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ARMY *TM 10-3930-675-23-1 MARINE CORPS TM 11078A-OI/1 VOLUME 1

TECHNICAL MANUAL FIELD MAINTENANCE MANUAL FOR

ROUGH TERRAIN CONTAINER HANDLER (RTCH): RT 240; 53,000 LB CAPACITY; 4 X 4 NSN 3930-01-473-3998 NSN 3930-01-522-7364

*SUPERSEDURE NOTICE: - This manual supersedes ARMY TM 10-3930-675-24-1 and TM 10-3930-675-24-2, and MARINE CORPS TM 11078A-IN/3 and TM 11078A-IN/4 dated 01 December 2006, including all changes. DISTRIBUTION STATEMENT A: - Approved for public release; distribution is unlimited.

HEADQUARTERS, DEPARTMENT OF THE ARMY HEADQUARTERS, U.S. MARINE CORPS 01 OCTOBER 2012 PCN 184 110783 00
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WARNING SUMMARY

This warning summary contains general safety warnings and hazardous materials warnings that must be understood and applied during operation and maintenance of this equipment. Failure to observe these precautions could result in serious injury or death to personnel. Also included are explanations of safety and hazardous materials icons used within the technical manual. FOR INFORMATION ON FIRST AID, REFER TO FM 4-25.11.

EXPLANATION OF SAFETY WARNING ICONS

ELECTRICAL - Electrical wire to arm with electricity symbol running through human body shows that shock hazard is present. May result in death or injury to personnel.

FLYING PARTICLES - Arrows bouncing off face with face shield shows that particles flying through the air will harm face. May result in death or injury to personnel.

HEAVY PARTS - Heavy object on human figure shows that heavy parts present a danger to life or limb. May result in death or injury to personnel.

HEAVY PARTS - Hand with heavy object on top shows that heavy parts can crush and harm. May result in death or injury to personnel.

HEAVY OBJECT - Human figure stooping over heavy object shows physical injury potential from improper lifting technique. May result in death or injury to personnel.

HOT AREA - Hand over object radiating heat shows that part is hot and can burn. May result in death or injury to personnel.

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GENERAL SAFETY WARNING DESCRIPTIONS

WARNING

COMPRESSED AIR Compressed air used for cleaning or drying purposes, or for cleaning restrictions, should never exceed 30 psi (207 kPa). Use protective equipment and exercise caution to avoid injury to personnel.

WARNING

ELECTRICAL SYSTEM MAINTENANCE Remove all jewelry, watches, rings, etc. prior to disconnecting cables from batteries or other electrical source. Items can come in contact with battery or electrical source and cause electrical shock. Failure to follow this warning may result in injury or death to personnel.

WARNING

HYDRAULIC SYSTEM DO NOT disconnect or remove any hydraulic system line or fitting unless hydraulic system pressure has been relieved. Tighten all connections before applying pressure. Escaping hydraulic fluid under pressure can penetrate the skin, causing serious injury. Search for leaks with a piece of cardboard. Protect hands and body from high-pressure fluids. If an accident occurs, see a doctor immediately. Any fluid injected into the skin must be surgically removed within a few hours or gangrene may result. At operating temperature, hydraulic oil is hot. Allow hydraulic oil to cool before disconnecting any hydraulic lines. Failure to follow this warning may result in injury to personnel. Hydraulic fluid is very slippery. Immediately wipe up any spills. Failure to follow this warning may result in injury to personnel.

WARNING
IR LIGHTS DO NOT look directly at IR source without eye protection and maintain a minimum of 12 inches from energized IR lights to prevent possible eye discomfort or damage.

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GENERAL SAFETY WARNING DESCRIPTIONS - Continued

WARNING

LIFTING HEAVY COMPONENTS Hydraulic jacks are intended only for lifting RTCH, not for supporting vehicle to perform maintenance. DO NOT get under vehicle after it is raised unless it is properly supported with blocks or other suitable cribbing. Failure to observe this warning may result in death or injury to personnel. Use extreme caution when handling heavy parts. Provide adequate support and use assistance during procedure. Ensure that any lifting device used is in good condition and of suitable load capacity. Keep clear of heavy parts supported only by lifting device. Failure to follow this warning may result in death or injury to personnel. Improper use of lifting equipment and improper attachment of cables to vehicle can result in serious personnel injury and equipment damage. Observe all standard rules of safety.

WARNING

SLAVE STARTING When slave starting RTCH, use NATO slave cable that DOES NOT have loose or missing insulation. DO NOT proceed if suitable cable is not available. DO NOT use civilian-type jumper cables.

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EXPLANATION OF HAZARDOUS MATERIALS ICONS

BIOLOGICAL - Abstract symbol bug shows that a material may contain bacteria or viruses that present a danger to life or health.

CHEMICAL - Drops of liquid on hand shows that the material will cause burns or irritation to human skin or tissue.

EYE PROTECTION - Person with goggles shows that the material will injure the eyes.

FIRE - Flame shows that a material may ignite and cause burns.

HYDRAULIC FLUID PRESSURE - Hydraulic fluid spraying human figure shows that fluid escaping under great pressure can cause injury or death.

RADIOACTIVE - Identifies a material that emits radioactive energy and can injure human tissue or organs.

VAPOR - Human figure in a cloud shows that material vapors present a danger to life or health.

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HAZARDOUS MATERIALS DESCRIPTIONS

WARNING

BATTERY Remove all jewelry, such as rings, I.D. tags, rings, bracelets, etc. If jewelry contacts a battery terminal, a direct short will result causing instant heating of jewelry. Failure to follow this warning may result in serious injury or death to personnel. Seek medical attention in the event of an injury. Battery acid (electrolyte) is extremely dangerous. Always wear eye protection and rubber gloves when performing battery checks or inspections. Serious injury to personnel will result if battery acid contacts skin or eyes. Failure to follow this warning may result in injury or death to personnel. Seek medical attention in the event of an injury. DO NOT perform battery system checks or inspections while smoking or near fire, flames, or sparks. Battery gases may explode. Failure to follow this warning may cause serious injury or death to personnel. Seek medical attention in the event of an injury. Sulfuric acid contained in batteries can cause serious burns. If battery corrosion or electrolyte makes contact with skin, eyes, or clothing, take immediate action to stop the corrosive burning effects. Failure to follow this warning may cause injury to personnel. Seek medical attention in the event of an injury. a. Eyes. Flush with cold water for no less than 15 minutes and immediately seek medical attention. b. Skin. Flush with large amounts of cold water until all acid is removed. Seek medical attention as required. c. Internal. If corrosion or electrolyte is ingested, drink large amounts of water or milk. Follow with milk of magnesia, beaten egg, or vegetable oil. Immediately seek medical attention. d. Clothing/Equipment. Wash area with large amounts of cold water. Neutralize acid with baking soda or household ammonia. California Proposition 65 Warning. Battery posts, terminals, and related accessories contain lead and lead components. These chemicals are known to the State of California to cause cancer and reproductive harm. Wash hands after handling. Failure to follow this warning may result in injury or death to personnel. Seek medical attention in the event of an injury.

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HAZARDOUS MATERIALS DESCRIPTIONS - Continued

WARNING

CARBON MONOXIDE (EXHAUST GASES) CAN KILL! Carbon monoxide is a colorless, odorless, deadly poisonous gas which, when breathed, deprives the body of oxygen and causes suffocation. Exposure to air containing carbon monoxide produces symptoms of headache, dizziness, loss of muscular control, apparent drowsiness, and coma. Permanent brain damage or death may result from severe exposure. Seek medical attention in the event of an injury. Carbon monoxide occurs in exhaust fumes of internal combustion engines. Carbon monoxide can become dangerously concentrated under conditions of inadequate ventilation. The following precautions must be observed to ensure safety of personnel when engine of RTCH is operated for any purpose. 1. DO NOT operate RTCH engine in enclosed areas. Good ventilation is essential. 2. BE ALERT at all times for exhaust odors. 3. BE ALERT for exhaust poisoning symptoms. They are: Headache Dizziness Drowsiness

Loss of muscular control 4. If you see another person with exhaust poisoning symptoms: Remove person from area. Expose person to fresh air. Keep person warm. DO NOT permit physical exercise. Administer cardiovascular pulmonary resuscitation (CPR), if necessary.

Notify a medic. 5. BE AWARE: The field protective mask for chemical-biological-radiological-nuclear (CBRN) protection will not protect you from carbon monoxide poisoning. 6. The Best Defense Against Carbon Monoxide Poisoning Is Good Ventilation. 7. Failure to follow this warning may result in injury or death to personnel. 8. Seek medical attention in the event of an injury.

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HAZARDOUS MATERIALS DESCRIPTIONS - Continued

WARNING

CBRN EXPOSURE If CBRN exposure is suspected, personnel wearing protective equipment must handle all air cleaner media. Contaminated filters must be handled using adequate precautions and must be disposed of by trained personnel. Consult your CBRN Officer or CBRN NCO for appropriate handling or disposal procedures. Failure to follow this warning may cause injury or death to personnel. Seek medical attention in the event of an injury.

To order this CBRN decal use: National Stock Number (NSN) - 7690-01-474-3533 Part Number (PN) - 1709220 Commercial and Government Entity Code (CAGEC) - 11083

WARNING

CLEANING AGENTS Improper cleaning methods and use of unauthorized cleaning agents can injure personnel and damage equipment. To prevent this, refer to TM 9-247 for further instructions.

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HAZARDOUS MATERIALS DESCRIPTIONS - Continued

WARNING

DIESEL FUEL HANDLING DO NOT perform fuel system checks, inspections, or maintenance while smoking or near fire, flames, or sparks. Fuel may ignite, causing damage to vehicle and injury or death to personnel. Wear fuel-resistant gloves when handling fuels and promptly wash exposed skin and change fuel-soaked clothing.

WARNING

CLEANING COMPOUND, SOLVENT Cleaning compound, solvent MIL-PRF-680 is toxic and flammable. Wear protective goggles and gloves and use only in a well-ventilated area. Avoid contact with skin, eyes, and clothes and do not breathe vapors. DO NOT use near open flames or excessive heat. The solvent's flash point is 200F (94C). If you become dizzy while using cleaning compound, solvent, get fresh air immediately and get medical aid. If solvent contacts eyes, wash your eyes and get medical aid immediately.

WARNING

ETHER COLD START Ether is extremely flammable and explosive. DO NOT perform ether cold start system checks, inspections or maintenance while smoking or near fire, flames or sparks. Failure to follow this warning may cause a fire and explosion, causing serious injury or death to personnel. Avoid breathing cold start system fluid vapors. Wear goggles and fuel-resistant gloves when handling fluid. Failure to follow this warning may result in serious injury or death to personnel.

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HAZARDOUS MATERIALS DESCRIPTIONS - Continued

WARNING

FIRE EXTINGUISHER Discharging large quantities of dry chemical fire extinguisher in cab may result in temporary breathing difficulty during and immediately after the discharge event. If at all possible, discharge fire extinguisher from outside the cab. Ventilate cab thoroughly prior to reentry.

WARNING

HAZARDOUS WASTE DISPOSAL When servicing this vehicle, performing maintenance, or disposing of materials such as engine coolant, hydraulic fluid, lubricants, battery acids or batteries, and CARC paint, consult your unit/local hazardous waste disposal center or safety office for local regulatory guidance. If further information is needed, please contact The Army Environmental Hotline at 1-800-327-3845. Failure to follow this warning may result in death or injury to personnel.

WARNING

PRESSURIZED COOLING SYSTEM DO NOT service cooling system unless engine has been allowed to cool down. This is a pressurized cooling system and escaping steam or hot coolant will cause serious burns. DO NOT remove cooling system radiator cap when engine is hot. Allow engine to cool down. Failure to follow this warning may cause serious burns. Wear effective eye, glove, and skin protection when handling coolants. Failure to follow this warning may result in injury.

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HAZARDOUS MATERIALS DESCRIPTIONS - Continued

WARNING

R-134A REFRIGERANT Liquid refrigerant, when exposed to air, quickly evaporates and will freeze skin or eye tissue. Take care to prevent refrigerant from touching your skin or eyes. Serious injury or blindness may result if you come in contact with liquid refrigerant. Refrigerant R-134a air conditioning systems should not be pressure tested or leak tested with compressed air. Combustible mixtures of air and R-134a may form, resulting in a fire or explosion, which could cause personnel injury.

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LIST OF EFFECTIVE PAGES/WORK PACKAGES


NOTE: This manual supersedes ARMY TM 10-3930-675-24-1 and TM 10-3930-675-24-2, and MARINE CORPS TM 11078A-IN/3 and TM 11078A-IN/4 dated 01 December 2006, including all changes. Zero in the "Change No." column indicates an original page or work package. This manual has two volumes. Date of issue for the original manual is: Original 01 OCTOBER 2012

TOTAL NUMBER OF PAGES FOR FRONT AND REAR MATTER IS 112 AND TOTAL NUMBER OF WORK PACKAGES IS 134 CONSISTING OF THE FOLLOWING: Page/WP No. VOLUME 1 Front Cover Promulgation Letter (2 pages) Warning Summary (10 pages) Title Block Page (2 pages) Table Of Contents (66 pages) How to Use This Manual (4 pages) Chapter 1 Title Page WP 0001 (4 pages) WP 0002 (8 pages) WP 0003 (4 pages) Chapter 2 Title Page WP 0004 (44 pages) WP 0005 (18 pages) WP 0006 (100 pages) WP 0007 (56 pages) WP 0008 (18 pages) WP 0009 (6 pages) WP 0010 (14 pages) WP 0011 (4 pages) WP 0012 (10 pages) WP 0013 (12 pages) WP 0014 (8 pages) WP 0015 (8 pages) WP 0016 (22 pages) WP 0017 (16 pages) WP 0018 (8 pages) WP 0019 (14 pages) WP 0020 (26 pages) WP 0021 (12 pages) WP 0022 (14 pages) WP 0023 (14 pages) WP 0024 (8 pages) WP 0025 (6 pages) WP 0026 (10 pages) WP 0027 (16 pages) WP 0028 (10 pages) WP 0029 (6 pages) WP 0030 (6 pages) Change No. 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 Page/WP No. WP 0031 (6 pages) WP 0032 (16 pages) WP 0033 (6 pages) WP 0034 (16 pages) WP 0035 (2 pages) WP 0036 (4 pages) WP 0037 (4 pages) WP 0038 (10 pages) WP 0039 (10 pages) WP 0040 (10 pages) WP 0041 (8 pages) WP 0042 (10 pages) WP 0043 (10 pages) WP 0044 (6 pages) WP 0045 (8 pages) WP 0046 (10 pages) Chapter 3 Title Page WP 0047 (2 pages) WP 0048 (8 pages) Chapter 4 Title Page WP 0049 (2 pages) WP 0050 (20 pages) WP 0051 (8 pages) WP 0052 (18 pages) WP 0053 (6 pages) WP 0054 (10 pages) WP 0055 (10 pages) WP 0056 (24 pages) WP 0057 (4 pages) WP 0058 (4 pages) WP 0059 (4 pages) WP 0060 (14 pages) WP 0061 (6 pages) WP 0062 (6 pages) WP 0063 (6 pages) WP 0064 (4 pages) WP 0065 (8 pages) WP 0066 (8 pages) WP 0067 (6 pages) Change No. 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0

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Page/WP No. WP 0068 (4 pages) WP 0069 (6 pages) WP 0070 (4 pages) WP 0071 (6 pages) WP 0072 (8 pages) WP 0073 (8 pages) WP 0074 (4 pages) WP 0075 (4 pages) WP 0076 (4 pages) WP 0077 (10 pages) WP 0078 (10 pages) WP 0079 (6 pages) WP 0080 (4 pages) WP 0081 (8 pages) WP 0082 (8 pages) WP 0083 (12 pages) WP 0084 (2 pages) WP 0085 (2 pages) WP 0086 (2 pages) WP 0087 (4 pages) WP 0088 (6 pages) WP 0089 (6 pages) WP 0090 (8 pages) WP 0091 (4 pages) WP 0092 (4 pages) WP 0093 (6 pages) WP 0094 (14 pages) WP 0095 (8 pages) WP 0096 (4 pages) WP 0097 (14 pages) WP 0098 (4 pages) WP 0099 (4 pages) WP 0100 (8 pages) WP 0101 (2 pages) WP 0102 (10 pages) WP 0103 (16 pages) WP 0104 (16 pages) WP 0105 (8 pages) WP 0106 (4 pages) WP 0107 (4 pages) WP 0108 (24 pages) WP 0109 (6 pages) WP 0110 (6 pages) WP 0111 (6 pages) WP 0112 (8 pages) WP 0113 (8 pages) WP 0114 (4 pages) WP 0115 (4 pages) WP 0116 (2 pages) WP 0117 (2 pages) WP 0118 (12 pages) Change No. 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 Page/WP No. WP 0119 (4 pages) WP 0120 (6 pages) WP 0121 (6 pages) WP 0122 (4 pages) WP 0123 (10 pages) WP 0124 (4 pages) WP 0125 (8 pages) WP 0126 (4 pages) WP 0127 (4 pages) WP 0128 (4 pages) WP 0129 (6 pages) WP 0130 (4 pages) WP 0131 (4 pages) WP 0132 (4 pages) WP 0133 (2 pages) WP 0134 (6 pages) Index (4 pages) Back Cover VOLUME 2 WP Front Cover (6 pages) Warning Summary (10 pages) Title Block Page (2 pages) Table Of Contents (4 pages) How To Use This Manual (4 pages) Chapter 5 Title Page WP 0135 (20 pages) WP 0136 (6 pages) WP 0137 (4 pages) WP 0138 (4 pages) WP 0139 (4 pages) WP 0140 (10 pages) WP 0141 (8 pages) WP 0142 (6 pages) WP 0143 (8 pages) WP 0144 (4 pages) WP 0145 (8 pages) WP 0146 (8 pages) WP 0147 (6 pages) WP 0148 (4 pages) WP 0149 (10 pages) WP 0150 (4 pages) WP 0151 (4 pages) WP 0152 (2 pages) WP 0153 (4 pages) WP 0154 (4 pages) WP 0155 (16 pages) WP 0156 (4 pages) WP 0157 (4 pages) WP 0158 (6 pages) WP 0159 (4 pages) WP 0160 (8 pages) Change No. 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0

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Page/WP No. WP 0161 (4 pages) WP 0162 (6 pages) WP 0163 (8 pages) WP 0164 (4 pages) WP 0165 (4 pages) WP 0166 (10 pages) WP 0167 (4 pages) WP 0168 (6 pages) WP 0169 (4 pages) WP 0170 (2 pages) WP 0171 (4 pages) WP 0172 (4 pages) WP 0173 (6 pages) WP 0174 (4 pages) WP 0175 (6 pages) WP 0176 (12 pages) WP 0177 (10 pages) WP 0178 (2 pages) WP 0179 (24 pages) WP 0180 (4 pages) WP 0181 (4 pages) WP 0182 (4 pages) WP 0183 (4 pages) WP 0184 (4 pages) WP 0185 (4 pages) WP 0186 (8 pages) WP 0187 (6 pages) WP 0188 (4 pages) WP 0189 (2 pages) WP 0190 (10 pages) WP 0191 (8 pages) WP 0192 (2 pages) WP 0193 (4 pages) WP 0194 (14 pages) WP 0195 (6 pages) WP 0196 (16 pages) WP 0197 (6 pages) WP 0198 (4 pages) WP 0199 (8 pages) WP 0200 (4 pages) WP 0201 (4 pages) WP 0202 (2 pages) WP 0203 (2 pages) WP 0204 (4 pages) WP 0205 (6 pages) WP 0206 (6 pages) WP 0207 (4 pages) WP 0208 (2 pages) WP 0209 (8 pages) WP 0210 (10 pages) WP 0211 (4 pages) Change No. 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 Page/WP No. WP 0212 (20 pages) WP 0213 (8 pages) WP 0214 (8 pages) WP 0215 (4 pages) WP 0216 (4 pages) WP 0217 (6 pages) WP 0218 (10 pages) WP 0219 (2 pages) WP 0220 (2 pages) WP 0221 (2 pages) WP 0222 (2 pages) WP 0223 (2 pages) WP 0224 (2 pages) WP 0225 (2 pages) WP 0226 (2 pages) WP 0227 (6 pages) WP 0228 (44 pages) WP 0229 (4 pages) WP 0230 (4 pages) WP 0231 (8 pages) WP 0232 (4 pages) WP 0233 (4 pages) WP 0234 (6 pages) WP 0235 (8 pages) WP 0236 (8 pages) WP 0237 (4 pages) WP 0238 (4 pages) WP 0239 (4 pages) WP 0240 (4 pages) WP 0241 (4 pages) WP 0242 (4 pages) WP 0243 (14 pages) WP 0244 (2 pages) WP 0245 (8 pages) WP 0246 (4 pages) WP 0247 (4 pages) WP 0248 (6 pages) WP 0249 (2 pages) WP 0250 (4 pages) WP 0251 (4 pages) WP 0252 (16 pages) WP 0253 (4 pages) WP 0254 (4 pages) WP 0255 (6 pages) WP 0256 (8 pages) WP 0257 (10 pages) WP 0258 (18 pages) WP 0259 (16 pages) WP 0260 (14 pages) WP 0261 (6 pages) WP 0262 (4 pages) Change No. 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0

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Page/WP No. WP 0263 (20 pages) WP 0264 (8 pages) WP 0265 (2 pages) WP 0266 (4 pages) WP 0267 (20 pages) WP 0268 (10 pages) WP 0269 (2 pages) WP 0270 (4 pages) WP 0271 (6 pages) WP 0272 (62 pages) Change No. 0 0 0 0 0 0 0 0 0 0 Page/WP No. Chapter 6 Title Page WP 0273 (2 pages) WP 0274 (4 pages) WP 0275 (28 pages) WP 0276 (6 pages) WP 0277 (8 pages) WP 0278 (10 pages) Index (8 pages) Back Cover Change No. 0 0 0 0 0 0 0 0 0

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*TM 10-3930-675-23-1 ARMY *TM 10-3930-675-23-1 MARINE CORPS TM 11078A-OI/1 HEADQUARTERS, DEPARTMENT OF THE ARMY HEADQUARTERS, U.S. MARINE CORPS WASHINGTON, D.C., 01 OCTOBER 2012 TECHNICAL MANUAL FIELD MAINTENANCE MANUAL

ROUGH TERRAIN CONTAINER HANDLER (RTCH): RT 240; 53,000 LB CAPACITY; 4 X 4 NSN 3930-01-473-3998 NSN 3930-01-522-7364
REPORTING ERRORS AND RECOMMENDING IMPROVEMENTS You can help improve this manual. If you find any mistakes or if you know of a way to improve the procedures, please let us know. Reports, as applicable by the requiring service, should be submitted as follows: (a) Army (A) - The preferred method is to submit your DA Form 2028 (Recommended Changes to Publications and Blank Forms) through the Internet on the TACOM Unique Logistics Support Applications (TULSA) website. The Internet address is https://tulsa.tacom.army.mil. The DA Form 2028 is located under the TULSA Applications on the left-hand navigation bar. Fill out the form and click on SUBMIT. Using this form on the TULSA website will enable us to respond more quickly to your comments and better manage the DA Form 2028 program. You may also mail, e-mail, or fax your comments or DA Form 2028 directly to the U.S. Army TACOM Life Cycle Management Command. The postal mail address is U.S. Army TACOM Life Cycle Management Command, ATTN: AMSTA-LCL-MPP / TECH PUBS, 6501 E. 11 Mile Road, Warren, MI 48397-5000. The e-mail address is tacomlcmc.daform2028@us.army.mil. The fax number is DSN 786-1856 or Commercial (586) 282-1856. (b) Marine Corps (MC) - Submit notice of discrepancies or suggested changes on a NAVMC 10772. The NAVMC may be submitted using either of the following: a. The preferred method of submittal is using https://portal.logcom.usmc.mil/sites/pubs/ URL which will allow direct connection to the LOGCOM SharePoint Pubs site (LOGCOM SharePoint access and CAC required) where the form can be filled out and be submitted to the NAVMC SharePoint database. Problems or questions regarding the NAVMC 10772 program should be reported by calling DSN 567-7628 or DSN 567-5017 (Commercial number is (229) 639-7628 or (229) 639-5017). b. The alternate method of submittal does not require a Common Access Card (CAC) to access the form. Click on http://navalforms.daps.dla.mil/web/public/forms, select the "Keyword Search" button, enter "10772" in the Search Criteria Box. Under "type" click on download page button. Click on PDF icon. Enter user data in the appropriate fields. Must have users contact information block filled with Unit address and telephone number. Click on the 'Envelope' icon in the tool bar. Select "Send Copy click on "OK". When the PDF document is created, an Outlook Email screen will open with the .PDF as an attachment. On the TO: line type SMB.LOG.Tech.Pubs.fct@usmc.mil. In the body of the email, type any additional information you wish to provide. Click SEND. c. A reply will be furnished to you.
*SUPERSEDURE NOTICE: - This manual supersedes ARMY TM 10-3930-675-24-1 and TM 10-3930-675-24-2, and MARINE CORPS TM 11078A-IN/3 and TM 11078A-IN/4 dated 01 December 2006, including all changes. DISTRIBUTION STATEMENT A - Approved for public release; distribution is unlimited. PCN 184 110783 00

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TABLE OF CONTENTS
Page No. WP Sequence No. Volume 1 HOW TO USE THIS MANUAL .......................................................................................................................... lxix Chapter 1 - GENERAL INFORMATION, EQUIPMENT DESCRIPTION, AND THEORY OF OPERATION GENERAL INFORMATION.......................................................................................................................... WP 0001 Table 1. List of Abbreviations/Acronyms............................................................................................ 0001-2

EQUIPMENT DESCRIPTION AND DATA................................................................................................... WP 0002 Figure 1. Table 1. Figure 2. Table 2. Figure 3. Table 3. Major Components............................................................................................................... 0002-2 Description of Major Components........................................................................................ 0002-2 Major Components............................................................................................................... 0002-3 Description of Major Components........................................................................................ 0002-3 Major Components............................................................................................................... 0002-4 Description of Major Components........................................................................................ 0002-4

THEORY OF OPERATION.......................................................................................................................... WP 0003 Chapter 2 - TROUBLESHOOTING PROCEDURES ERROR CODE REFERENCES................................................................................................................... WP 0004 Table 1. Table 2. Table 3. Table 4. Driver Action Icons............................................................................................................... 0004-1 Type of Fault Icons............................................................................................................... 0004-1 Function Icons...................................................................................................................... 0004-2 Error Code Reference Index................................................................................................ 0004-4

TROUBLESHOOTING SYMPTOM INDEX.................................................................................................. WP 0005 TROUBLESHOOTING PROCEDURES (NON-ERROR CODE)................................................................. WP 0006 Figure 1. Starter Motor........................................................................................................................ 0006-3

ENGINE FUEL INJECTOR CIRCUITS TROUBLESHOOTING................................................................... WP 0007 Figure 1. Figure 2. Figure 3. Figure 4. Actuator Harness Test.......................................................................................................... 0007-3 Actuator Harness Test.......................................................................................................... 0007-5 Actuator Harness Test.......................................................................................................... 0007-8 Actuator Harness Test........................................................................................................ 0007-11

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Page No. WP Sequence No. Figure 5. Figure 6. Figure 7. Figure 8. Figure 9. Figure 10. Figure 11. Figure 12. Figure 13. Figure 14. Figure 15. Figure 16. Figure 17. Figure 18. Figure 19. Figure 20. Figure 21. Figure 22. Figure 23. Figure 24. Figure 25. Figure 26. Figure 27. Figure 28. Figure 29. Figure 30. Figure 31. Actuator Harness Test........................................................................................................ 0007-13 Actuator Harness Test........................................................................................................ 0007-16 Actuator Harness Test........................................................................................................ 0007-18 Actuator Harness Test........................................................................................................ 0007-19 Actuator Harness Test........................................................................................................ 0007-20 15-Pin Connector Test....................................................................................................... 0007-21 15-Pin Connector Test....................................................................................................... 0007-22 Solenoid Connector Test.................................................................................................... 0007-23 Actuator Harness Test........................................................................................................ 0007-24 Actuator Harness Connector Test...................................................................................... 0007-25 Actuator Harness Connector Test...................................................................................... 0007-26 Injector Wiring Test............................................................................................................ 0007-27 Actuator Harness Test........................................................................................................ 0007-28 Solenoid Connector Test.................................................................................................... 0007-29 Actuator Harness Test........................................................................................................ 0007-30 Actuator Harness Test........................................................................................................ 0007-31 Actuator Harness Test........................................................................................................ 0007-32 Injector Wiring Test............................................................................................................ 0007-33 Injector Wiring Test............................................................................................................ 0007-34 Injector Wiring Test............................................................................................................ 0007-35 Actuator Harness Test........................................................................................................ 0007-36 Actuator Harness Test........................................................................................................ 0007-37 Actuator Harness Test........................................................................................................ 0007-38 Injector Wiring Test............................................................................................................ 0007-39 Actuator Harness Test........................................................................................................ 0007-40 Actuator Harness Test........................................................................................................ 0007-41 Actuator Harness Test........................................................................................................ 0007-42

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Page No. WP Sequence No. Figure 32. Figure 33. Figure 34. Figure 35. Figure 36. Figure 37. Figure 38. Figure 39. Figure 40. Figure 41. Figure 42. Figure 43. Figure 44. Figure 45. Figure 46. Figure 47. Figure 48. Actuator Harness Test........................................................................................................ 0007-43 Actuator Harness Test........................................................................................................ 0007-44 Actuator Harness Test........................................................................................................ 0007-45 Actuator Harness Test........................................................................................................ 0007-46 Actuator Harness Test........................................................................................................ 0007-47 Actuator Harness Test........................................................................................................ 0007-48 Actuator Harness Test........................................................................................................ 0007-49 Actuator Harness Test........................................................................................................ 0007-50 Actuator Harness Test........................................................................................................ 0007-51 Actuator Harness Test........................................................................................................ 0007-52 Actuator Harness Test........................................................................................................ 0007-53 Cylinder #1 Supply and Return.......................................................................................... 0007-54 Cylinder #5 Supply and Return.......................................................................................... 0007-54 Cylinder #3 Supply and Return.......................................................................................... 0007-55 Cylinder #6 Supply and Return.......................................................................................... 0007-55 Cylinder #2 Supply and Return.......................................................................................... 0007-56 Cylinder #4 Supply and Return.......................................................................................... 0007-56

ENGINE TPS AND VALIDATION SWITCH TROUBLESHOOTING............................................................ WP 0008 Figure 1. Figure 2. Figure 3. Figure 4. Figure 5. Figure 6. Figure 7. Figure 8. Figure 9. Accelerator Pedal Wiring Test.............................................................................................. 0008-3 Accelerator Pedal Wiring Test.............................................................................................. 0008-4 OEM Harness Connector Test............................................................................................. 0008-5 OEM Harness Connector Test............................................................................................. 0008-5 OEM Harness Connector Test............................................................................................. 0008-6 Accelerator Pedal Wiring Test.............................................................................................. 0008-8 Accelerator Pedal Wiring Test.............................................................................................. 0008-9 OEM Wiring Harness Test.................................................................................................. 0008-10 OEM Wiring Harness Test.................................................................................................. 0008-10

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Page No. WP Sequence No. Figure 10. Figure 11. Figure 12. Figure 13. Figure 14. Figure 15. Figure 16. Accelerator Pedal Calibration............................................................................................. 0008-11 Accelerator Pedal Test....................................................................................................... 0008-12 Accelerator Pedal Resistance Test.................................................................................... 0008-13 Idle Validation Circuit Voltage Test.................................................................................... 0008-13 Idle Validation Circuit Voltage Test.................................................................................... 0008-14 TPS and Idle Validation Circuit Voltage Test..................................................................... 0008-16 TPS and Idle Validation Circuit Voltage Test..................................................................... 0008-17

COOLING FAN OPERATION AND FAN CONTROL TROUBLESHOOTING............................................. WP 0009 Figure 1. Cooling Fan Diagnostics...................................................................................................... 0009-5

OVERLOAD PROTECTION TROUBLESHOOTING................................................................................... WP 0010 Figure 1. Figure 2. Overload Protection Diagnostics........................................................................................ 0010-12 Overload Protection Diagnostics........................................................................................ 0010-13

TOPHANDLER ELECTRONIC CONTROL UNIT (ECU) (791) TROUBLESHOOTING............................... WP 0011 Figure 1. Tophandler ECU Diagnostics............................................................................................... 0011-3

ELECTRONIC CONTROL UNIT (ECU) INPUT VOLTAGE TROUBLESHOOTING.................................... WP 0012 Figure 1. Figure 2. Figure 3. ECU Input Diagnostics......................................................................................................... 0012-8 ECU Input Diagnostics......................................................................................................... 0012-9 ECU Input Diagnostics....................................................................................................... 0012-10

ECU-TO-ECU COMMUNICATIONS TROUBLESHOOTING....................................................................... WP 0013 STEERING ECU (792), TRANSMISSION ECU (793), AND ENGINE ECU (794) TROUBLESHOOTING................................................................................................................................. WP 0014 Figure 1. Figure 2. Figure 3. Figure 4. Figure 5. Use Test Lead Kit................................................................................................................. 0014-4 Engine ECU Circuit Test...................................................................................................... 0014-5 Engine ECU Circuit Test...................................................................................................... 0014-6 Engine ECU Circuit Test...................................................................................................... 0014-7 Engine ECU Test.................................................................................................................. 0014-8

ELECTRONIC CONTROL UNIT (ECU) SUPPLY VOLTAGE TROUBLESHOOTING................................ WP 0015 INPUT AND OUTPUT SIGNALS FOR STEERING ECU (792) TROUBLESHOOTING.............................. WP 0016

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Page No. WP Sequence No. ENGINE ELECTRONIC CONTROL UNIT (ECU) (794) TROUBLESHOOTING......................................... WP 0017 Figure 1. Figure 2. Figure 3. Figure 4. Figure 5. Figure 6. Figure 7. Figure 8. Figure 9. Figure 10. Figure 11. Figure 12. Figure 13. Figure 14. Figure 15. Figure 16. Oil Pressure/Temperature Sensor Voltage Test.................................................................. 0017-2 Oil Pressure/Temperature Sensor Voltage Test.................................................................. 0017-3 Oil Pressure/Temperature Sensor Voltage Test.................................................................. 0017-4 Oil Pressure/Temperature Sensor Voltage Test.................................................................. 0017-5 Sensor Voltage Supply Test................................................................................................. 0017-6 Sensor Voltage Supply Test................................................................................................. 0017-7 Sensor Voltage Supply Test................................................................................................. 0017-7 Sensor Voltage Supply Test................................................................................................. 0017-8 Sensor Voltage Supply Test................................................................................................. 0017-9 Sensor Voltage Supply Test................................................................................................. 0017-9 Sensor Voltage Supply Test............................................................................................... 0017-10 Sensor Voltage Supply Test............................................................................................... 0017-11 Sensor Voltage Supply Test............................................................................................... 0017-12 Sensor Voltage Supply Test............................................................................................... 0017-13 OEM Harness Connector Circuit Check............................................................................. 0017-15 Oil Pressure/Temperature Sensor Circuits......................................................................... 0017-15

ENGINE POSITION SENSOR CIRCUITS TROUBLESHOOTING.............................................................. WP 0018 Figure 1. Figure 2. Figure 3. Figure 4. Figure 5. Engine Harness Circuit Resistance Check........................................................................... 0018-3 Engine Harness Circuit Resistance Check........................................................................... 0018-4 Engine Harness Circuit Resistance Check........................................................................... 0018-6 Engine Harness Circuit Resistance Check........................................................................... 0018-7 Engine Position Sensor Circuits........................................................................................... 0018-8

ENGINE OIL PRESSURE SENSOR TROUBLESHOOTING...................................................................... WP 0019 Figure 1. Figure 2. Figure 3. Oil Pressure Sensor Voltage Supply Test............................................................................ 0019-2 Oil Pressure Sensor Voltage Supply Test............................................................................ 0019-3 Oil Pressure Sensor Voltage Supply Test............................................................................ 0019-3

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Page No. WP Sequence No. Figure 4. Figure 5. Figure 6. Figure 7. Figure 8. Figure 9. Figure 10. Figure 11. Figure 12. Figure 13. Oil Pressure Sensor Circuit Resistance Test....................................................................... 0019-4 Oil Pressure Sensor Circuit Resistance Test....................................................................... 0019-5 Oil Pressure Sensor Circuit Voltage Test............................................................................. 0019-6 Oil Pressure Sensor Circuit Voltage Test............................................................................. 0019-7 Oil Pressure Sensor Test..................................................................................................... 0019-7 Oil Pressure Sensor Circuit Resistance Test....................................................................... 0019-8 Oil Pressure Sensor Circuit Resistance Test....................................................................... 0019-9 Oil Pressure Sensor Circuit Resistance Test..................................................................... 0019-10 Oil Pressure Sensor Circuit Failure Test............................................................................ 0019-11 Oil Pressure Sensor Circuit Identification........................................................................... 0019-13

ENGINE TEMPERATURE SENSORS AND CIRCUITS TROUBLESHOOTING......................................... WP 0020 Figure 1. Figure 2. Figure 3. Figure 4. Figure 5. Figure 6. Figure 7. Figure 8. Figure 9. Figure 10. Figure 11. Figure 12. Figure 13. Figure 14. Figure 15. Figure 16. Coolant Temperature Sensor Test....................................................................................... 0020-3 Coolant Temperature Sensor Circuit Resistance Test......................................................... 0020-4 Coolant Temperature Sensor Circuit Resistance Test......................................................... 0020-5 Coolant Temperature Sensor Resistance Test.................................................................... 0020-6 Coolant Temperature Sensor Resistance Test.................................................................... 0020-7 Coolant Temperature Sensor Circuit Resistance Test......................................................... 0020-8 Coolant Temperature Sensor Circuit Resistance Test......................................................... 0020-9 Intake Air Temperature Sensor Resistance Test............................................................... 0020-10 Intake Air Temperature Sensor Circuit Resistance Test.................................................... 0020-11 Intake Air Temperature Sensor Circuit Resistance Test.................................................... 0020-12 Intake Air Temperature Sensor Resistance Test............................................................... 0020-13 Intake Air Temperature Sensor Resistance Test............................................................... 0020-13 Intake Air Temperature Sensor Circuit Resistance Test.................................................... 0020-14 Intake Air Temperature Sensor Circuit Resistance Test.................................................... 0020-15 Oil Temperature Sensor Resistance Test.......................................................................... 0020-17 Oil Temperature Sensor Circuit Resistance Test............................................................... 0020-18

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Page No. WP Sequence No. Figure 17. Figure 18. Figure 19. Figure 20. Figure 21. Figure 22. Figure 23. Oil Temperature Sensor Circuit Resistance Test............................................................... 0020-19 Oil Temperature Sensor Resistance Test.......................................................................... 0020-20 Oil Temperature Sensor Resistance Test.......................................................................... 0020-21 Oil Temperature Sensor Circuit Resistance Test............................................................... 0020-22 Oil Temperature Sensor Circuit Resistance Test............................................................... 0020-23 Engine Sensors Replacement............................................................................................ 0020-24 Intake Manifold Temperature Sensor Circuit Information................................................... 0020-25

ENGINE AMBIENT AIR PRESSURE SENSOR AND CIRCUITS TROUBLESHOOTING.......................... WP 0021 Figure 1. Figure 2. Table 1. Figure 3. Figure 4. Figure 5. Figure 6. Figure 7. Table 2. Figure 8. Figure 9. Figure 10. Figure 11. Figure 12. Ambient Air Temperature Sensor Voltage Test.................................................................... 0021-3 Ambient Air Temperature Sensor Circuit Voltage Test........................................................ 0021-3 Altitude (Ft.) vs. Voltage....................................................................................................... 0021-4 Ambient Air Temperature Sensor Circuit Voltage Test........................................................ 0021-4 Ambient Air Temperature Sensor Circuit Resistance Test................................................... 0021-5 Ambient Air Temperature Sensor Circuit Resistance Test................................................... 0021-5 Ambient Air Temperature Sensor Circuit Voltage Test........................................................ 0021-6 Ambient Air Temperature Sensor Circuit Voltage Test........................................................ 0021-7 Altitude (Ft.) vs. Voltage....................................................................................................... 0021-8 Ambient Air Temperature Sensor Circuit Voltage Test........................................................ 0021-8 Ambient Air Temperature Sensor Circuit Voltage Test........................................................ 0021-9 Ambient Air Temperature Sensor Circuit Voltage Test........................................................ 0021-9 Ambient Air Temperature Sensor Circuit Resistance Test................................................. 0021-10 Ambient Air Temperature Sensor Circuit Test.................................................................... 0021-11

ENGINE PRESSURE SENSOR TROUBLESHOOTING............................................................................. WP 0022 Figure 1. Figure 2. Figure 3. Figure 4. Intake Manifold Pressure Sensor Circuit Voltage Test......................................................... 0022-3 Intake Manifold Pressure Sensor Circuit Voltage Test......................................................... 0022-3 Intake Manifold Pressure Sensor Circuit Voltage Test......................................................... 0022-4 Intake Manifold Pressure Sensor Circuit Voltage Test......................................................... 0022-4

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Page No. WP Sequence No. Figure 5. Figure 6. Figure 7. Figure 8. Figure 9. Figure 10. Figure 11. Figure 12. Figure 13. Figure 14. Figure 15. Figure 16. Figure 17. Figure 18. Intake Manifold Pressure Sensor Circuit Resistance Test................................................... 0022-5 Intake Manifold Pressure Sensor Circuit Resistance Test................................................... 0022-6 Intake Manifold Pressure Sensor Circuit Resistance Test................................................... 0022-7 Intake Manifold Pressure Sensor Circuit Voltage Test......................................................... 0022-8 Intake Manifold Pressure Sensor Circuit Voltage Test......................................................... 0022-9 Intake Manifold Pressure Sensor Circuit Voltage Test......................................................... 0022-9 Intake Manifold Pressure Sensor Circuit Resistance Test................................................. 0022-10 Intake Manifold Pressure Sensor Circuit Resistance Test................................................. 0022-10 Intake Manifold Pressure Sensor Circuit Resistance Test................................................. 0022-11 Intake Manifold Pressure Sensor Circuit Test.................................................................... 0022-11 Intake Manifold Pressure Sensor Circuit Resistance Test................................................. 0022-13 Intake Manifold Pressure Sensor Circuit Resistance Test................................................. 0022-13 Intake Manifold Pressure Sensor Circuit Resistance Test................................................. 0022-14 Intake Manifold Pressure Sensor Circuit Information......................................................... 0022-14

ENGINE FUEL PRESSURE SENSORS AND CIRCUITS TROUBLESHOOTING...................................... WP 0023 Figure 1. Figure 2. Figure 3. Figure 4. Figure 5. Figure 6. Figure 7. Figure 8. Figure 9. Figure 10. Figure 11. Figure 12. Fuel Shutoff Solenoid Post Inspection................................................................................. 0023-2 Fuel Shutoff Solenoid Voltage Test...................................................................................... 0023-2 Fuel Shutoff Valve Actuator Wire......................................................................................... 0023-3 Fuel Shutoff Solenoid Circuit Resistance Test..................................................................... 0023-4 Fuel Shutoff Solenoid Circuit Voltage Test........................................................................... 0023-5 Fuel Shutoff Solenoid Circuit Resistance Test..................................................................... 0023-5 Fuel Shutoff Solenoid Circuit Voltage Test........................................................................... 0023-6 Fuel Shutoff Solenoid Circuit Resistance Test..................................................................... 0023-7 Fuel Inlet Restriction Sensor Circuit Resistance Test.......................................................... 0023-8 Fuel Inlet Restriction Sensor Circuit Voltage Test................................................................ 0023-9 Fuel Inlet Restriction Sensor Circuit Voltage Test................................................................ 0023-9 Fuel Inlet Restriction Sensor Circuit Voltage Test.............................................................. 0023-10

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Page No. WP Sequence No. Figure 13. Figure 14. Figure 15. Fuel Inlet Restriction Sensor Circuit Resistance Test........................................................ 0023-11 Fuel Inlet Restriction Sensor Circuit Resistance Test........................................................ 0023-12 Fuel Inlet Restriction Sensor Circuit Resistance Test........................................................ 0023-13

ENGINE BATTERY VOLTAGE CIRCUITS TROUBLESHOOTING............................................................ WP 0024 Figure 1. Figure 2. Figure 3. Figure 4. Figure 5. OEM Harness Circuit Resistance Test................................................................................. 0024-3 Starter Solenoid Lockout Relay Circuit Resistance Test...................................................... 0024-6 Starter Solenoid Lockout Relay Circuit Continuity Test........................................................ 0024-7 Battery Cranking Voltage Test............................................................................................. 0024-8 Alternator Charging Amperage Test..................................................................................... 0024-8

TRANSMISSION TEMPERATURE TROUBLESHOOTING........................................................................ WP 0025 Figure 1. Component Locations.......................................................................................................... 0025-6

TRANSMISSION SPEED SENSORS TROUBLESHOOTING..................................................................... WP 0026 Figure 1. Component Locations........................................................................................................ 0026-10

TRANSMISSION CLUTCH CIRCUIT TROUBLESHOOTING..................................................................... WP 0027 MISCELLANEOUS TRANSMISSION FAILURE TROUBLESHOOTING..................................................... WP 0028 INTERNAL TRANSMISSION CLUTCH SLIPPAGE FAILURE TROUBLESHOOTING............................... WP 0029 BRAKE SYSTEM TROUBLESHOOTING.................................................................................................... WP 0030 Figure 1. Component Locations.......................................................................................................... 0030-6

AXLE BRAKE COOLING SYSTEM TROUBLESHOOTING........................................................................ WP 0031 STEERING VALVE CIRCUIT TROUBLESHOOTING................................................................................. WP 0032 Figure 1. Connector 770 Numbering................................................................................................. 0032-14

MECHANICAL OR HYDRAULIC STEERING FAILURE TROUBLESHOOTING........................................ WP 0033 STEERING SENSOR TROUBLESHOOTING............................................................................................. WP 0034 HYDRAULIC SERVO SYSTEM ELECTRONIC CONTROL UNIT (ECU) (790) TROUBLESHOOTING................................................................................................................................. WP 0035 Figure 1. Component Locations.......................................................................................................... 0035-2

AUXILIARY PUMP TROUBLESHOOTING.................................................................................................. WP 0036 HYDRAULIC PISTON PUMP CUT-OFF TROUBLESHOOTING................................................................ WP 0037

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Page No. WP Sequence No. Figure 1. Component Locations.......................................................................................................... 0037-3

HYDRAULIC FILTER INDICATORS TROUBLESHOOTING...................................................................... WP 0038 Figure 1. Figure 2. Component Locations.......................................................................................................... 0038-8 Component Locations.......................................................................................................... 0038-9

BOOM LIFTING/LOWERING TROUBLESHOOTING................................................................................. WP 0039 Figure 1. Figure 2. Component Locations.......................................................................................................... 0039-9 Component Locations........................................................................................................ 0039-10

BOOM IN/OUT TROUBLESHOOTING........................................................................................................ WP 0040 Figure 1. Figure 2. Component Locations.......................................................................................................... 0040-7 Component Locations.......................................................................................................... 0040-8

TOPHANDLER SLEWING TROUBLESHOOTING...................................................................................... WP 0041 Figure 1. Figure 2. Component Locations.......................................................................................................... 0041-7 Component Locations.......................................................................................................... 0041-8

TOPHANDLER TILT TROUBLESHOOTING............................................................................................... WP 0042 Figure 1. Figure 2. Component Locations.......................................................................................................... 0042-9 Component Locations........................................................................................................ 0042-10

TOPHANDLER LEVELING TROUBLESHOOTING..................................................................................... WP 0043 Figure 1. Figure 2. Component Locations. ........................................................................................................ 0043-8 Component Locations. ........................................................................................................ 0043-9

TOPHANDLER SIDESHIFT TROUBLESHOOTING................................................................................... WP 0044 Figure 1. Component Locations.......................................................................................................... 0044-6

TOPHANDLER SPREADER TROUBLESHOOTING.................................................................................. WP 0045 Figure 1. Component Locations.......................................................................................................... 0045-7

TOPHANDLER TWISTLOCKS AND FORKLIFT SENSOR TROUBLESHOOTING.................................... WP 0046 Figure 1. Figure 2. Figure 3. Tophandler Twistlocks Indication Failure............................................................................. 0046-3 Component Locations.......................................................................................................... 0046-8 Component Locations.......................................................................................................... 0046-9

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Page No. WP Sequence No. Chapter 3 - PREVENTIVE MAINTENANCE CHECKS AND SERVICES (PMCS) PREVENTIVE MAINTENANCE CHECKS AND SERVICES (PMCS) Introduction...................................... WP 0047 Table 1. Leakage Definitions for PMCS............................................................................................. 0047-1

PREVENTIVE MAINTENANCE CHECKS AND SERVICES (PMCS)......................................................... WP 0048 Table 1. Table 2. Preventive Maintenance Checks and Services (PMCS) for the RTCH................................ 0048-1 PMCS Mandatory Replacement Parts List........................................................................... 0048-8

Chapter 4 - MAINTENANCE INSTRUCTIONS SERVICE UPON RECEIPT......................................................................................................................... WP 0049 ENGINE ASSEMBLY REPLACEMENT....................................................................................................... WP 0050 Figure 1. Figure 2. Figure 3. Figure 4. Figure 5. Figure 6. Figure 7. Figure 8. Figure 9. Figure 10. Figure 11. Figure 12. Figure 13. Figure 14. Figure 15. Figure 16. Figure 17. Figure 18. Engine Removal................................................................................................................... 0050-3 Engine Removal................................................................................................................... 0050-4 Engine Removal................................................................................................................... 0050-5 Engine Removal................................................................................................................... 0050-5 Engine Removal................................................................................................................... 0050-6 Engine Removal................................................................................................................... 0050-7 Engine Removal................................................................................................................... 0050-7 Engine Removal................................................................................................................... 0050-8 Engine Removal................................................................................................................... 0050-9 Engine Removal................................................................................................................. 0050-10 Engine Installation.............................................................................................................. 0050-12 Engine Installation.............................................................................................................. 0050-13 Engine Installation.............................................................................................................. 0050-13 Engine Installation.............................................................................................................. 0050-14 Engine Installation.............................................................................................................. 0050-14 Engine Installation.............................................................................................................. 0050-15 Engine Installation.............................................................................................................. 0050-16 Engine Installation.............................................................................................................. 0050-17

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Page No. WP Sequence No. Figure 19. Figure 20. Engine Installation.............................................................................................................. 0050-18 Engine Installation.............................................................................................................. 0050-19

ENGINE MOUNTS AND LIFTING BRACKETS REPLACEMENT............................................................... WP 0051 Figure 1. Figure 2. Figure 3. Figure 4. Lifting Brackets Removal...................................................................................................... 0051-2 Lifting Brackets Installation................................................................................................... 0051-3 Front Engine Mount Installation............................................................................................ 0051-5 Rear Engine Mount Removal............................................................................................... 0051-7

CYLINDER HEAD REPLACEMENT............................................................................................................ WP 0052 Figure 1. Figure 2. Figure 3. Figure 4. Figure 5. Figure 6. Figure 7. Figure 8. Figure 9. Figure 10. Figure 11. Figure 12. Figure 13. Table 1. Figure 14. Figure 15. Figure 16. Figure 17. Figure 18. Cylinder Head Removal....................................................................................................... 0052-1 Cylinder Head Removal....................................................................................................... 0052-2 Cylinder Head Removal....................................................................................................... 0052-2 Cylinder Head Removal....................................................................................................... 0052-3 Cylinder Head Removal....................................................................................................... 0052-3 Cylinder Head Removal....................................................................................................... 0052-4 Cylinder Head Removal....................................................................................................... 0052-4 Cylinder Head Removal....................................................................................................... 0052-5 Cylinder Head Removal....................................................................................................... 0052-5 Cylinder Head Removal....................................................................................................... 0052-6 Cylinder Head Inspection..................................................................................................... 0052-8 Cylinder Head Inspection..................................................................................................... 0052-9 Cylinder Head Inspection................................................................................................... 0052-10 Cylinder Head Flatness Measurements............................................................................. 0052-10 Cylinder Head Inspection................................................................................................... 0052-11 Cylinder Head Inspection................................................................................................... 0052-11 Cylinder Head Installation.................................................................................................. 0052-12 Cylinder Head Installation.................................................................................................. 0052-13 Cylinder Head Installation.................................................................................................. 0052-13

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Page No. WP Sequence No. Figure 19. Figure 20. Figure 21. Figure 22. Figure 23. Figure 24. Cylinder Head Installation.................................................................................................. 0052-14 Cylinder Head Installation.................................................................................................. 0052-14 Cylinder Head Installation.................................................................................................. 0052-15 Cylinder Head Installation.................................................................................................. 0052-15 Cylinder Head Removal..................................................................................................... 0052-16 Cylinder Head Installation.................................................................................................. 0052-16

VIBRATION DAMPER REPLACEMENT..................................................................................................... WP 0053 Figure 1. Figure 2. Figure 3. Figure 4. Figure 5. Vibration Damper Removal.................................................................................................. 0053-2 Thickness Measure.............................................................................................................. 0053-3 Eccentricity Check................................................................................................................ 0053-3 Wobble Check...................................................................................................................... 0053-4 Vibration Damper Installation............................................................................................... 0053-5

FLYWHEEL ASSEMBLY REPLACEMENT................................................................................................. WP 0054 Figure 1. Figure 2. Figure 3. Figure 4. Figure 5. Table 1. Figure 6. Figure 7. Flywheel Assembly Removal............................................................................................... 0054-2 Flywheel Assembly Removal............................................................................................... 0054-3 Flywheel Assembly Removal............................................................................................... 0054-4 Flywheel Assembly Inspection............................................................................................. 0054-5 Flywheel Assembly Inspection............................................................................................. 0054-6 Flywheel Face Runout.......................................................................................................... 0054-7 Flywheel Assembly Installation............................................................................................ 0054-8 Flywheel Assembly Installation............................................................................................ 0054-9

REAR MAIN OIL SEAL REPLACEMENT.................................................................................................... WP 0055 Figure 1. Figure 2. Figure 3. Figure 4. Figure 5. Rear Main Oil Seal Removal................................................................................................ 0055-2 Wear Sleeve Removal.......................................................................................................... 0055-3 Wear Sleeve Removal.......................................................................................................... 0055-3 Wear Sleeve Removal.......................................................................................................... 0055-4 Wear Sleeve Removal.......................................................................................................... 0055-4

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Page No. WP Sequence No. Figure 6. Figure 7. Figure 8. Figure 9. Figure 10. Figure 11. Figure 12. Rear Main Oil Seal and Thick Wear Sleeve Installation....................................................... 0055-5 Rear Main Oil Seal and Thick Wear Sleeve Installation....................................................... 0055-6 Rear Main Oil Seal and Thick Wear Sleeve Installation....................................................... 0055-6 Rear Main Oil Seal and Thick Wear Sleeve Installation....................................................... 0055-7 Rear Main Oil Seal and Thick Wear Sleeve Installation....................................................... 0055-7 Rear Main Oil Seal and Thick Wear Sleeve Installation....................................................... 0055-8 Rear Main Oil Seal and Thick Wear Sleeve Installation....................................................... 0055-9

ROCKER ARM ASSEMBLY MAINTENANCE............................................................................................. WP 0056 Figure 1. Figure 2. Figure 3. Figure 4. Figure 5. Figure 6. Figure 7. Figure 8. Figure 9. Figure 10. Figure 11. Figure 12. Figure 13. Figure 14. Figure 15. Figure 16. Figure 17. Figure 18. Figure 19. Push Rods and Push Tubes Removal................................................................................. 0056-2 Key Stock Installation........................................................................................................... 0056-2 Front Rocker Arm Assembly Removal................................................................................. 0056-3 Rocker Levers Removal....................................................................................................... 0056-4 Rocker Lever Disassembly................................................................................................... 0056-4 Rocker Lever Bushing Measurement................................................................................... 0056-5 Rocker Lever Shaft Measurement........................................................................................ 0056-5 Rocker Arm Shaft Assembly................................................................................................ 0056-6 Rocker Arm Shaft Assembly................................................................................................ 0056-7 Rocker Arm Shaft Assembly................................................................................................ 0056-7 Rocker Arm Shaft Assembly................................................................................................ 0056-8 Rocker Arm Shaft Installation............................................................................................... 0056-8 Rocker Arm Shaft Installation............................................................................................... 0056-9 Rocker Arm Shaft Installation............................................................................................... 0056-9 Rocker Arm Shaft Installation............................................................................................. 0056-10 Rocker Arm Shaft Installation............................................................................................. 0056-10 Rocker Arm Shaft Installation. ........................................................................................... 0056-11 Rocker Arm Shaft Installation............................................................................................. 0056-11 Rocker Arm Shaft Installation............................................................................................. 0056-12

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Page No. WP Sequence No. Figure 20. Figure 21. Figure 22. Table 1. Figure 23. Figure 24. Table 2. Figure 25. Figure 26. Table 3. Figure 27. Figure 28. Figure 29. Figure 30. Figure 31. Figure 32. Figure 33. Figure 34. Rocker Arm Shaft Installation............................................................................................. 0056-12 Rocker Arm Shaft Installation............................................................................................. 0056-13 Valve Lash Check.............................................................................................................. 0056-14 Injector and Valve Measurement Sequence...................................................................... 0056-15 Valve Lash Check.............................................................................................................. 0056-15 Valve Lash Check.............................................................................................................. 0056-16 M Series Valve Lash Recheck Limits................................................................................. 0056-16 Injector Lash Check............................................................................................................ 0056-17 Injector Lash Check............................................................................................................ 0056-18 M Series Injector Lash Recheck Limits.............................................................................. 0056-18 Injector Adjustment............................................................................................................. 0056-19 Injector Adjustment............................................................................................................. 0056-19 Valve Adjustment............................................................................................................... 0056-20 Valve Adjustment............................................................................................................... 0056-21 Valve Adjustment............................................................................................................... 0056-21 Valve Adjustment............................................................................................................... 0056-22 Valve Adjustment............................................................................................................... 0056-22 Valve Adjustment............................................................................................................... 0056-23

ROCKER ARM COVER AND GASKET REPLACEMENT........................................................................... WP 0057 Figure 1. Figure 2. Rocker Arm Cover and Gasket Replacement...................................................................... 0057-2 Rocker Arm Cover Tightening Sequence............................................................................. 0057-3

OIL PAN REPLACEMENT........................................................................................................................... WP 0058 Figure 1. Figure 2. Figure 3. Oil Pan Removal.................................................................................................................. 0058-2 Oil Pan Installation............................................................................................................... 0058-3 Oil Pan Installation............................................................................................................... 0058-3

ENGINE OIL AND OIL FILTER REPLACEMENT........................................................................................ WP 0059 Figure 1. Drain Engine Oil................................................................................................................... 0059-2

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Page No. WP Sequence No. Figure 2. Oil Filter and Gasket............................................................................................................. 0059-3

OIL FILTER HEAD AND OIL COOLER MAINTENANCE............................................................................ WP 0060 Figure 1. Figure 2. Figure 3. Figure 4. Figure 5. Figure 6. Figure 7. Figure 8. Figure 9. Figure 10. Figure 11. Figure 12. Figure 13. Oil Filter Head and Oil Cooler Removal............................................................................... 0060-2 Oil Filter Head and Oil Cooler Removal............................................................................... 0060-2 Oil Filter Head and Oil Cooler Removal............................................................................... 0060-3 Oil Filter Head and Oil Cooler Disassembly......................................................................... 0060-5 Oil Cooler Testing................................................................................................................. 0060-7 Oil Cooler Cleaning.............................................................................................................. 0060-8 Oil Cooler Pressure Test...................................................................................................... 0060-9 Oil Filter Head Assembly...................................................................................................... 0060-9 Oil Filter Head Assembly.................................................................................................... 0060-10 Oil Filter Head Installation.................................................................................................. 0060-10 Oil Filter Head and Oil Cooler Installation.......................................................................... 0060-11 Oil Filter Head and Oil Cooler Installation.......................................................................... 0060-12 Oil Filter Head and Oil Cooler Installation.......................................................................... 0060-12

ENGINE OIL DIPSTICK HOSE AND OIL FILL HOSE REPLACEMENT..................................................... WP 0061 Figure 1. Figure 2. Figure 3. Engine Oil Dipstick Replacement and Fill Hose Removal.................................................... 0061-3 Oil Dipstick Cover and Cylinder Block Cleaning................................................................... 0061-4 Engine Oil Dipstick and Fill Hoses Installation..................................................................... 0061-5

OIL SAMPLING VALVES AND HOSES REPLACEMENT.......................................................................... WP 0062 Figure 1. Figure 2. Figure 3. Figure 4. Oil Sampling Valve............................................................................................................... 0062-2 Engine Oil Sampling Valve Hose......................................................................................... 0062-3 Transmission Oil Sampling Valve Hose............................................................................... 0062-4 Hydraulic System Oil Sampling Valve Hose......................................................................... 0062-5

EXHAUST MANIFOLD REPLACEMENT.................................................................................................... WP 0063 Figure 1. Figure 2. Exhaust Manifold Removal................................................................................................... 0063-1 Exhaust Manifold Removal................................................................................................... 0063-2

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Page No. WP Sequence No. Figure 3. Figure 4. Figure 5. Exhaust Manifold Installation................................................................................................ 0063-3 Exhaust Manifold Installation................................................................................................ 0063-4 Exhaust Manifold Installation................................................................................................ 0063-5

INTAKE MANIFOLD REPLACEMENT........................................................................................................ WP 0064 Figure 1. Figure 2. Figure 3. Intake Manifold Removal...................................................................................................... 0064-1 Intake Manifold Installation................................................................................................... 0064-2 Intake Manifold Sequence.................................................................................................... 0064-2

FRONT GEAR COVER REPLACEMENT.................................................................................................... WP 0065 Figure 1. Figure 2. Figure 3. Figure 4. Figure 5. Figure 6. Figure 7. Figure 8. Front Gear Cover Removal.................................................................................................. 0065-2 Front Gear Cover Removal.................................................................................................. 0065-3 Front Gear Cover Removal.................................................................................................. 0065-3 Front Gear Cover Installation............................................................................................... 0065-4 Front Gear Cover Installation............................................................................................... 0065-5 Front Gear Cover Installation............................................................................................... 0065-5 Front Gear Cover Installation............................................................................................... 0065-6 Front Gear Cover Tightening Sequence.............................................................................. 0065-7

FRONT MAIN OIL SEAL REPLACEMENT.................................................................................................. WP 0066 Figure 1. Figure 2. Figure 3. Figure 4. Figure 5. Figure 6. Figure 7. Figure 8. Figure 9. Figure 10. Front Main Oil Seal Removal............................................................................................... 0066-1 Front Main Oil Seal Removal............................................................................................... 0066-2 Unitized Front Crankshaft Main Oil Seal Removal............................................................... 0066-2 Unitized Front Crankshaft Main Oil Seal Removal............................................................... 0066-3 Cleaning and Inspection....................................................................................................... 0066-3 Front Unitized Crankshaft Main Oil Seal Installation............................................................ 0066-4 Front Unitized Crankshaft Main Oil Seal Installation............................................................ 0066-5 Front Unitized Crankshaft Main Oil Seal Installation............................................................ 0066-5 Front Unitized Crankshaft Main Oil Seal Installation............................................................ 0066-6 Front Unitized Crankshaft Main Oil Seal Installation............................................................ 0066-7

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Page No. WP Sequence No. FUEL INJECTOR REPLACEMENT............................................................................................................. WP 0067 Figure 1. Figure 2. Figure 3. Figure 4. Figure 5. Figure 6. Push Rods and Push Tubes Removal................................................................................. 0067-2 Injector Hold-Down Clamp Removal.................................................................................... 0067-3 Injector Removal.................................................................................................................. 0067-3 Injector Installation............................................................................................................... 0067-4 Injector Installation............................................................................................................... 0067-5 Push Rods and Push Tubes Installation.............................................................................. 0067-5

FUEL PUMP ASSEMBLY REPLACEMENT................................................................................................ WP 0068 Figure 1. Fuel Pump Removal............................................................................................................. 0068-3

FUEL HOSES, LINES, AND FITTINGS REPLACEMENT........................................................................... WP 0069 Figure 1. Figure 2. Figure 3. Figure 4. Cooling Plate-to-Cylinder Head Fuel Line............................................................................ 0069-2 Fuel Pump-to-Cooling Plate Fuel Line................................................................................. 0069-3 Engine Fuel Return Line....................................................................................................... 0069-4 Fuel Return Hose................................................................................................................. 0069-5

FUEL SOLENOID SHUTOFF VALVE REPLACEMENT.............................................................................. WP 0070 Figure 1. Figure 2. Figure 3. Fuel Solenoid Shutoff Valve Removal.................................................................................. 0070-2 Fuel Solenoid Shutoff Valve Installation............................................................................... 0070-3 Fuel Solenoid Shutoff Valve Installation............................................................................... 0070-3

ENGINE AIR CLEANER MAINTENANCE................................................................................................... WP 0071 Figure 1. Figure 2. Figure 3. Figure 4. Engine Air Cleaner............................................................................................................... 0071-2 Engine Air Cleaner Filter Elements Removal....................................................................... 0071-3 Engine Air Cleaner Filter Elements Removal and Installation.............................................. 0071-4 Engine Air Cleaner Filter Elements Removal and Installation.............................................. 0071-5

ENGINE AIR INTAKE HOSES AND TUBES REPLACEMENT................................................................... WP 0072 Figure 1. Figure 2. Figure 3. Air Cleaner-to-Turbocharger Hoses and Tubes................................................................... 0072-3 Turbocharger-to-Charge Air Cooler Hoses and Tubes........................................................ 0072-5 Charger Air Cooler-to-Engine Air Intake Manifold Hoses and Tubes................................... 0072-7

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Page No. WP Sequence No. TURBOCHARGER REPLACEMENT.......................................................................................................... WP 0073 Figure 1. Figure 2. Figure 3. Figure 4. Figure 5. Figure 6. Figure 7. Figure 8. Figure 9. Figure 10. Clamps Removal.................................................................................................................. 0073-2 Turbocharger Removal......................................................................................................... 0073-2 Turbocharger Removal......................................................................................................... 0073-3 Turbocharger Removal......................................................................................................... 0073-3 Turbocharger Axial Clearance Check.................................................................................. 0073-4 Turbocharger Radial Bearing Clearance Check................................................................... 0073-5 Turbocharger Installation...................................................................................................... 0073-6 Turbocharger Installation...................................................................................................... 0073-6 Turbocharger Installation...................................................................................................... 0073-7 Turbocharger Installation...................................................................................................... 0073-7

FUEL TANK REPLACEMENT..................................................................................................................... WP 0074 Figure 1. Figure 2. Fuel Tank Removal.............................................................................................................. 0074-2 Fuel Tank Replacement....................................................................................................... 0074-3

FUEL SUPPLY AND RETURN HOSES REPLACEMENT.......................................................................... WP 0075 Figure 1. Fuel Supply Hose................................................................................................................. 0075-3

FUEL FILTER/WATER SEPARATOR REPLACEMENT............................................................................. WP 0076 Figure 1. Figure 2. Figure 3. Fuel Pump Ball Valve........................................................................................................... 0076-2 Fuel Filter............................................................................................................................. 0076-3 Fuel Pump Ball Valve........................................................................................................... 0076-4

ETHER COLD START SYSTEM MAINTENANCE...................................................................................... WP 0077 Figure 1. Figure 2. Figure 3. Figure 4. Figure 5. Figure 6. Ether Canister Removal....................................................................................................... 0077-1 Ether Canister Gasket.......................................................................................................... 0077-2 Ether Canister Installation.................................................................................................... 0077-3 Cold Start Activation Solenoid Removal............................................................................... 0077-4 Cold Start Activation Solenoid Removal............................................................................... 0077-5 Cold Start Activation Solenoid Removal............................................................................... 0077-5

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Page No. WP Sequence No. Figure 7. Figure 8. Figure 9. Figure 10. Cold Start Activation Solenoid Removal............................................................................... 0077-6 Cold Start Activation Solenoid Installation............................................................................ 0077-7 Cold Start Activation Solenoid Installation............................................................................ 0077-8 Cold Start Activation Solenoid Installation............................................................................ 0077-9

THROTTLE POSITION SENSOR (ACCELERATOR PEDAL) REPLACEMENT........................................ WP 0078 Figure 1. Figure 2. Figure 3. Figure 4. Figure 5. Figure 6. Figure 7. Figure 8. Figure 9. Figure 10. Figure 11. Figure 12. Throttle Position Sensor Removal - RT 240V1 and RT 240V1R.......................................... 0078-1 Throttle Position Sensor Removal - RT 240V1 and RT 240V1R.......................................... 0078-2 Throttle Position Sensor Removal - RT 240V1 and RT 240V1R.......................................... 0078-2 Throttle Position Sensor Removal - RT 240V2 and RT 240V3............................................ 0078-3 Throttle Position Sensor Removal - RT 240V2 and RT 240V3............................................ 0078-3 Throttle Position Sensor Removal - RT 240V2 and RT 240V3............................................ 0078-4 Throttle Position Sensor Installation - RT 240V2 and RT 240V3......................................... 0078-5 Throttle Position Sensor Installation - RT 240V2 and RT 240V3......................................... 0078-6 Throttle Position Sensor Installation - RT 240V2 and RT 240V3......................................... 0078-7 Throttle Position Sensor Installation - RT 240V1 and RT 240V1R....................................... 0078-8 Throttle Position Sensor Installation - RT 240V1 and RT 240V1R....................................... 0078-9 Throttle Position Sensor Installation - RT 240V1 and RT 240V1R....................................... 0078-9

MUFFLER AND EXHAUST PIPE REPLACEMENT.................................................................................... WP 0079 Figure 1. Figure 2. Muffler and Exhaust Pipe Removal...................................................................................... 0079-3 Muffler and Exhaust Pipe Installation................................................................................... 0079-5

DRAINING AND FILLING RADIATOR ASSEMBLY.................................................................................... WP 0080 Figure 1. Figure 2. Figure 3. Figure 4. Drain Radiator Assembly...................................................................................................... 0080-2 Fill Radiator Assembly.......................................................................................................... 0080-3 Fill Radiator Assembly.......................................................................................................... 0080-3 Check Coolant Level............................................................................................................ 0080-4

RADIATOR ASSEMBLY MAINTENANCE................................................................................................... WP 0081 Figure 1. Angle Plate Removal............................................................................................................ 0081-2

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Page No. WP Sequence No. Figure 2. Figure 3. Figure 4. Figure 5. Figure 6. Radiator Grille Removal....................................................................................................... 0081-3 Radiator Removal................................................................................................................. 0081-4 Radiator Installation.............................................................................................................. 0081-5 Radiator Grille Installation.................................................................................................... 0081-6 Angle Plate Installation......................................................................................................... 0081-7

COOLING SYSTEM EXPANSION TANK MAINTENANCE......................................................................... WP 0082 Figure 1. Figure 2. Figure 3. Figure 4. Figure 5. Figure 6. Cooling System Expansion Tank Removal.......................................................................... 0082-2 Cooling System Expansion Tank Removal.......................................................................... 0082-3 Cooling System Expansion Tank Removal.......................................................................... 0082-4 Cooling System Expansion Tank Assembly and Installation................................................ 0082-5 Cooling System Expansion Tank Installation....................................................................... 0082-6 Cooling System Expansion Tank Installation....................................................................... 0082-7

COOLING SYSTEM HOSES REPLACEMENT........................................................................................... WP 0083 Figure 1. Figure 2. Figure 3. Figure 4. Figure 5. Figure 6. Figure 7. Figure 8. Figure 9. Figure 10. Cab Interface Unit-to-Water Pump Hose.............................................................................. 0083-2 Cab Interface Unit-to-Engine Block Hose............................................................................. 0083-3 Coolant Reservoir-to-Radiator Hose.................................................................................... 0083-4 Coolant Reservoir-to-Water Manifold Hose.......................................................................... 0083-5 Coolant Reservoir-to-Water Pump Hose.............................................................................. 0083-6 Transmission Oil Cooler-to-Radiator Hoses......................................................................... 0083-7 Transmission Oil Cooler-to-Water Pump Hoses.................................................................. 0083-8 Transmission Oil Cooler-to-Water Pump Return Hose........................................................ 0083-9 Transmission Oil Cooler U-Hose........................................................................................ 0083-10 Water Manifold-to-Radiator Hoses..................................................................................... 0083-11

RADIATOR SPLASH SHIELD REPLACEMENT......................................................................................... WP 0084 Figure 1. Radiator Splash Shield Installation....................................................................................... 0084-2

RADIATOR TOP GRATING REPLACEMENT............................................................................................. WP 0085 Figure 1. Radiator Top Grating Replacement...................................................................................... 0085-2

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Page No. WP Sequence No. RADIATOR FILL COVER PLATE REPLACEMENT.................................................................................... WP 0086 Figure 1. Radiator Fill Cover Replacement......................................................................................... 0086-1

THERMOSTAT REPLACEMENT................................................................................................................ WP 0087 Figure 1. Figure 2. Figure 3. Figure 4. Thermostat Removal............................................................................................................ 0087-1 Thermostat Removal............................................................................................................ 0087-2 Thermostat Removal and Installation................................................................................... 0087-2 Thermostat Installation......................................................................................................... 0087-3

WATER PUMP REPLACEMENT................................................................................................................. WP 0088 Figure 1. Figure 2. Figure 3. Figure 4. Figure 5. Figure 6. Figure 7. Water Pump Pulley Removal............................................................................................... 0088-2 Dust and Oil Seal Removal.................................................................................................. 0088-3 Water Pump Removal.......................................................................................................... 0088-3 Needle Bearing Inspection................................................................................................... 0088-4 Water Pump Installation....................................................................................................... 0088-5 Oil and Dust Seal Installation............................................................................................... 0088-5 Water Pump Pulley Installation............................................................................................ 0088-6

HYDRAULIC COOLING FAN MAINTENANCE........................................................................................... WP 0089 Figure 1. Figure 2. Cooling Fan Removal........................................................................................................... 0089-3 Cooling Fan Installation........................................................................................................ 0089-5

COOLANT FILTER AND FILTER HEAD REPLACEMENT......................................................................... WP 0090 Figure 1. Figure 2. Figure 3. Figure 4. Figure 5. Coolant Filter Removal......................................................................................................... 0090-2 Coolant Filter Preparation.................................................................................................... 0090-3 Coolant Filter Tightening...................................................................................................... 0090-4 Turn Coolant Filter Head Valve ON...................................................................................... 0090-5 Coolant Filter Head Replacement........................................................................................ 0090-7

ALTERNATOR REPLACEMENT................................................................................................................. WP 0091 Figure 1. Figure 2. Alternator Removal............................................................................................................... 0091-1 Alternator Removal............................................................................................................... 0091-2

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Page No. WP Sequence No. Figure 3. Alternator Installation............................................................................................................ 0091-3

ALTERNATOR DRIVE BELT MAINTENANCE............................................................................................ WP 0092 Figure 1. Figure 2. Figure 3. Alternator Drive Belt Removal.............................................................................................. 0092-1 Alternator Drive Belt Installation........................................................................................... 0092-2 Alternator Drive Belt Adjustment.......................................................................................... 0092-3

STARTER MOTOR REPLACEMENT.......................................................................................................... WP 0093 Figure 1. Figure 2. Figure 3. Figure 4. Figure 5. Starter Removal................................................................................................................... 0093-2 Starter Removal................................................................................................................... 0093-3 Starter Removal................................................................................................................... 0093-3 Starter Installation................................................................................................................ 0093-4 Starter Installation................................................................................................................ 0093-5

INSTRUMENT PANEL SWITCHES, GAUGES, AND PANEL LAMPS REPLACEMENT............................ WP 0094 Figure 1. Figure 2. Figure 3. Figure 4. Figure 5. Figure 6. Figure 7. Figure 8. Figure 9. Figure 10. Figure 11. Figure 12. Figure 13. Switch/Gauge Panel Removal.............................................................................................. 0094-2 Rocker Switch Removal....................................................................................................... 0094-3 Switch/Gauge Panel Removal.............................................................................................. 0094-4 Rotary Switch Removal........................................................................................................ 0094-5 Rotary Switch Removal and Installation............................................................................... 0094-7 Switch/Gauge Panel Installation........................................................................................... 0094-7 Rotary Switch Installation..................................................................................................... 0094-8 Gauge Removal................................................................................................................... 0094-9 Switch/Gauge Panel Installation......................................................................................... 0094-10 Instrument Panel Lamp Installation.................................................................................... 0094-11 Instrument Panel Lamp Installation.................................................................................... 0094-12 12/24 Connector Removal.................................................................................................. 0094-13 12/24V Connector Installation............................................................................................ 0094-14

TRANSMISSION AND ACCESSORY CONTROL LEVERS REPLACEMENT............................................ WP 0095 Figure 1. Separate Housing................................................................................................................. 0095-1

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Page No. WP Sequence No. Figure 2. Figure 3. Figure 4. Figure 5. Figure 6. Figure 7. Figure 8. Figure 9. Transmission and Accessory Control Levers Removal........................................................ 0095-2 Panel Removed.................................................................................................................... 0095-3 Panel Removal..................................................................................................................... 0095-3 Transmission and Accessory Control Levers Removal........................................................ 0095-4 Transmission and Accessory Control Levers Installation..................................................... 0095-5 Panels Installation................................................................................................................ 0095-6 Panels Installation................................................................................................................ 0095-6 Housing Installation.............................................................................................................. 0095-7

ECS DISPLAY SCREEN REPLACEMENT................................................................................................. WP 0096 Figure 1. Figure 2. Figure 3. ECS Display Screen Removal.............................................................................................. 0096-1 ECS Display Screen Installation........................................................................................... 0096-2 ECS Display Screen Installation........................................................................................... 0096-3

TOPHANDLER JUNCTION BOX MAINTENANCE..................................................................................... WP 0097 Figure 1. Figure 2. Figure 3. Figure 4. Figure 5. Figure 6. Figure 7. Figure 8. Figure 9. Figure 10. Figure 11. Figure 12. Figure 13. Figure 14. Tophandler ECU Removal................................................................................................... 0097-2 Tophandler ECU Installation................................................................................................ 0097-3 Relay Installation.................................................................................................................. 0097-4 Tophandler Junction Box Removal...................................................................................... 0097-5 Tophandler Junction Box Removal...................................................................................... 0097-5 Tophandler Junction Box Removal...................................................................................... 0097-6 Tophandler Junction Box Removal...................................................................................... 0097-7 Tophandler Junction Box Removal...................................................................................... 0097-8 Tophandler Junction Box Removal...................................................................................... 0097-9 Tophandler Junction Box Replacement............................................................................. 0097-10 Tophandler Junction Box Installation................................................................................. 0097-11 Tophandler Junction Box Installation................................................................................. 0097-12 Tophandler Junction Box Installation................................................................................. 0097-13 Tophandler Junction Box Installation................................................................................. 0097-13

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Page No. WP Sequence No. TOPHANDLER PROXIMITY SWITCH JUNCTION BOXES REPLACEMENT............................................ WP 0098 Figure 1. Figure 2. Figure 3. Tophandler Junction Box Cover Removal............................................................................ 0098-1 Tophandler Junction Box Replacement............................................................................... 0098-3 Tophandler Junction Box Cover Installation......................................................................... 0098-4

ENGINE ELECTRONIC CONTROL UNIT (ECU) REPLACEMENT............................................................ WP 0099 Figure 1. ECU Replacement................................................................................................................ 0099-3

ELECTRONIC CONTROL UNITS (ECU) REPLACEMENT........................................................................ WP 0100 Figure 1. Figure 2. Figure 3. Figure 4. Figure 5. Figure 6. Figure 7. Figure 8. Access Panels Removal....................................................................................................... 0100-1 Transmission ECU Removal................................................................................................ 0100-2 Access Panels Removal....................................................................................................... 0100-3 Steering System ECU Removal........................................................................................... 0100-4 Seat Base Cover Removal................................................................................................... 0100-5 Hydraulic Servo System ECU Removal............................................................................... 0100-6 Hydraulic Servo System ECU Installation............................................................................ 0100-7 Seat Base Cover Installation................................................................................................ 0100-8

ELECTRONIC JOYSTICK ASSEMBLY REPLACEMENT........................................................................... WP 0101 Figure 1. Figure 2. Joystick Removal................................................................................................................. 0101-1 Joystick Installation.............................................................................................................. 0101-2

ELECTRONIC JOYSTICK ASSEMBLY WIRING HARNESS REPLACEMENT.......................................... WP 0102 Figure 1. Figure 2. Figure 3. Figure 4. Figure 5. Figure 6. Figure 7. Figure 8. Joystick Wiring Harness Removal........................................................................................ 0102-2 Joystick Wiring Harness Removal........................................................................................ 0102-3 Joystick Wiring Harness Removal........................................................................................ 0102-4 Seat Base Cover Removal................................................................................................... 0102-5 Joystick Wiring Harness Removal........................................................................................ 0102-5 Joystick Wiring Harness Removal........................................................................................ 0102-6 Joystick Wiring Harness Installation..................................................................................... 0102-7 Seat Base Cover Installation................................................................................................ 0102-7

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Page No. WP Sequence No. Figure 9. Figure 10. Joystick Wiring Harness Installation..................................................................................... 0102-8 Joystick Wiring Harness Installation..................................................................................... 0102-9

CIRCUIT BREAKERS AND RELAYS REPLACEMENT.............................................................................. WP 0103 Figure 1. Figure 2. Figure 3. Figure 4. Figure 5. Figure 6. Figure 7. Figure 8. Figure 9. Figure 10. Figure 11. Figure 12. Figure 13. Figure 14. Figure 15. Figure 16. Access Panel Removal........................................................................................................ 0103-1 Circuit Breaker/Relay Box Opening...................................................................................... 0103-2 Circuit Breaker Panel Separation......................................................................................... 0103-3 Circuit Breaker Removal...................................................................................................... 0103-3 Circuit Breaker Removal...................................................................................................... 0103-4 Relay Removal..................................................................................................................... 0103-5 Relay Replacement.............................................................................................................. 0103-6 Relay Connection................................................................................................................. 0103-7 Circuit Breaker Connection.................................................................................................. 0103-8 Circuit Breaker Installation................................................................................................... 0103-9 Circuit Breaker Panel Installation......................................................................................... 0103-9 Circuit Breaker Panel Installation....................................................................................... 0103-10 Access Panel Installation................................................................................................... 0103-11 Circuit Breaker Installation................................................................................................. 0103-13 Starter Relay Installation.................................................................................................... 0103-14 Fuse Block Installation....................................................................................................... 0103-15

TOPHANDLER PROXIMITY SWITCHES REPLACEMENT........................................................................ WP 0104 Figure 1. Figure 2. Figure 3. Figure 4. Figure 5. Figure 6. Figure 7. Twistlock Proximity Switch Removal.................................................................................... 0104-2 Junction Box Cover Removal............................................................................................... 0104-3 Twistlock Proximity Switch Installation................................................................................. 0104-5 Junction Box Cover Installation............................................................................................ 0104-5 Twistlock Proximity Switch Installation................................................................................. 0104-6 Forklift Interlock Proximity Switch Removal......................................................................... 0104-7 Junction Box Cover Removal............................................................................................... 0104-7

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Page No. WP Sequence No. Figure 8. Figure 9. Figure 10. Figure 11. Figure 12. Figure 13. Figure 14. Figure 15. Figure 16. Figure 17. Forklift Interlock Proximity Switch Removal......................................................................... 0104-8 Forklift Interlock Proximity Switch Removal......................................................................... 0104-9 Junction Box Cover Installation............................................................................................ 0104-9 Twistlock Proximity Switch Installation............................................................................... 0104-10 Spreader Beam Proximity Switch Removal........................................................................ 0104-11 Spreader Beam Proximity Switch Removal........................................................................ 0104-11 Spreader Beam Proximity Switch Removal........................................................................ 0104-12 Spreader Beam Proximity Switch Installation..................................................................... 0104-13 Spreader Beam Proximity Switch Installation..................................................................... 0104-14 Spreader Beam Proximity Switch Installation..................................................................... 0104-15

CAB POSITION PROXIMITY SWITCHES REPLACEMENT....................................................................... WP 0105 Figure 1. Figure 2. Figure 3. Figure 4. Figure 5. Figure 6. Figure 7. Cab-Mounted Proximity Switch Removal............................................................................. 0105-1 Cab-Mounted Proximity Switch Removal............................................................................. 0105-2 Cab-Mounted Proximity Switch Replacement...................................................................... 0105-3 Cab-Mounted Proximity Switch Installation.......................................................................... 0105-4 Cab Support-Mounted Proximity Switch Removal............................................................... 0105-5 Cab Support-Mounted Proximity Switch Installation............................................................ 0105-7 Cab-Support Mounted Proximity Switch Installation............................................................ 0105-8

SOLAR CHARGER REPLACEMENT (IF EQUIPPED)................................................................................ WP 0106 Figure 1. Figure 2. Figure 3. Figure 4. Figure 5. Solar Charger Replacement................................................................................................. 0106-1 Solar Charger Replacement................................................................................................. 0106-2 Solar Charger Replacement................................................................................................. 0106-3 Solar Charger Replacement................................................................................................. 0106-3 Solar Charger Replacement................................................................................................. 0106-4

BOOM WIRING HARNESSES REPLACEMENT........................................................................................ WP 0107 Figure 1. Figure 2. Boom Wiring Harness Removal........................................................................................... 0107-1 Boom Wiring Harness Removal........................................................................................... 0107-2

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Page No. WP Sequence No. Figure 3. Boom Wiring Harness Installation........................................................................................ 0107-3

TOPHANDLER WIRING HARNESSES REPLACEMENT........................................................................... WP 0108 Figure 1. Figure 2. Figure 3. Figure 4. Figure 5. Figure 6. Figure 7. Figure 8. Figure 9. Figure 10. Figure 11. Figure 12. Figure 13. Figure 14. Figure 15. Figure 16. Figure 17. Figure 18. Figure 19. Figure 20. Figure 21. Figure 22. Figure 23. Figure 24. Figure 25. Wiring Harness A Removal.................................................................................................. 0108-2 Wiring Harness A Removal.................................................................................................. 0108-3 Wiring Harness A Removal.................................................................................................. 0108-3 Wiring Harness A Installation............................................................................................... 0108-5 Wiring Harness A Installation............................................................................................... 0108-5 Wiring Harness B Removal.................................................................................................. 0108-6 Wiring Harness B Removal.................................................................................................. 0108-7 Wiring Harness B Installation............................................................................................... 0108-8 Wiring Harness B Installation............................................................................................... 0108-9 Wiring Harness C Removal................................................................................................ 0108-10 Wiring Harness C Removal................................................................................................ 0108-11 Wiring Harness C Installation............................................................................................. 0108-12 Wiring Harness C Installation............................................................................................. 0108-13 Wiring Harness D Removal................................................................................................ 0108-13 Wiring Harness D Removal................................................................................................ 0108-14 Wiring Harness D Removal................................................................................................ 0108-15 Wiring Harness D Removal................................................................................................ 0108-16 Wiring Harness D Installation............................................................................................. 0108-17 Wiring Harness D Installation............................................................................................. 0108-18 Wiring Harness D Installation............................................................................................. 0108-18 Wiring Harness E Removal................................................................................................ 0108-19 Wiring Harness E Removal................................................................................................ 0108-20 Wiring Harness E Removal................................................................................................ 0108-21 Wiring Harness E Installation............................................................................................. 0108-22 Wiring Harness E Installation............................................................................................. 0108-23

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Page No. WP Sequence No. Figure 26. Wiring Harness E Installation............................................................................................. 0108-23

HEADLIGHT MAINTENANCE..................................................................................................................... WP 0109 Figure 1. Figure 2. Figure 3. Figure 4. Headlight Reflector Insert Removal...................................................................................... 0109-2 Headlight Bulb Replacement................................................................................................ 0109-3 Headlight Reflector Insert Installation................................................................................... 0109-3 Light Removal and Installation............................................................................................. 0109-5

BACKUP LIGHT AND WORK LIGHT MAINTENANCE............................................................................... WP 0110 Figure 1. Figure 2. Figure 3. Figure 4. Reflector Insert Removal...................................................................................................... 0110-2 Bulb Replacement................................................................................................................ 0110-3 Reflector Insert Installation................................................................................................... 0110-3 Light Removal and Installation............................................................................................. 0110-5

BLACKOUT LIGHT MAINTENANCE........................................................................................................... WP 0111 Figure 1. Figure 2. Figure 3. Figure 4. Bulb/Reflector Replacement................................................................................................. 0111-2 Bulb/Reflector Replacement................................................................................................. 0111-3 Bulb/Reflector Replacement................................................................................................. 0111-3 Blackout Light Replacement................................................................................................. 0111-5

DIRECTIONAL BULB AND SIDE MARKER LIGHTS MAINTENANCE....................................................... WP 0112 Figure 1. Figure 2. Figure 3. Figure 4. Figure 5. Figure 6. Lens Removal...................................................................................................................... 0112-2 Bulb and LED Replacement................................................................................................. 0112-3 Lens Installation................................................................................................................... 0112-3 Directional Light Replacement............................................................................................. 0112-5 Side Marker Light Cover Removal....................................................................................... 0112-6 Bulb Replacement................................................................................................................ 0112-7

TWISTLOCK INDICATOR LIGHTS MAINTENANCE.................................................................................. WP 0113 Figure 1. Figure 2. Figure 3. Twistlock Indicator Light Bulb Replacement. ....................................................................... 0113-2 Twistlock Indicator Light Bulb Replacement......................................................................... 0113-3 Twistlock Indicator Light Removal........................................................................................ 0113-4

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Page No. WP Sequence No. Figure 4. Figure 5. Twistlock Indicator Light Installation..................................................................................... 0113-5 Twistlock Infrared (IR) Light Replacement........................................................................... 0113-7

CAB INTERIOR LIGHT MAINTENANCE..................................................................................................... WP 0114 Figure 1. Figure 2. Cab Interior Light Bulb Removal.......................................................................................... 0114-1 Cab Interior Light Bulb Installation....................................................................................... 0114-3

INFRARED (IR) LIGHTS REPLACEMENT.................................................................................................. WP 0115 Figure 1. Figure 2. Infrared (IR) Light Removal.................................................................................................. 0115-2 Infrared (IR) Light Installation............................................................................................... 0115-3

FORDING WATER LEVEL SENSOR REPLACEMENT.............................................................................. WP 0116 Figure 1. Figure 2. Water Level Sensor Removal............................................................................................... 0116-1 Water Level Sensor Installation............................................................................................ 0116-2

WHEEL TEMPERATURE SENSOR REPLACEMENT................................................................................ WP 0117 Figure 1. Wheel Temperature Sensor Replacement........................................................................... 0117-2

ENGINE SENSORS REPLACEMENT......................................................................................................... WP 0118 Figure 1. Figure 2. Figure 3. Figure 4. Figure 5. Figure 6. Figure 7. Figure 8. Coolant Temperature Sensor Replacement......................................................................... 0118-3 Engine Position Sensor Removal......................................................................................... 0118-4 Intake Air Temperature Sensor Replacement...................................................................... 0118-5 Intake Manifold Pressure Sensor Replacement................................................................... 0118-6 Ambient Air Pressure Sensor Replacement......................................................................... 0118-7 Ambient Air Pressure Sensor Removal (New Style)............................................................ 0118-8 Ambient Temperature Sensor Installation (New Style)........................................................ 0118-9 Oil Pressure/Temperature Sensor Replacement............................................................... 0118-10

HYDRAULIC FILTER INDICATOR SENSORS REPLACEMENT............................................................... WP 0119 Figure 1. Hydraulic Cylinder Filter Indicator Sensor Replacement...................................................... 0119-3

TRANSMISSION SENSORS REPLACEMENT........................................................................................... WP 0120 Figure 1. Figure 2. Transmission Sensors.......................................................................................................... 0120-2 Transmission Sensor Connector.......................................................................................... 0120-3

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Page No. WP Sequence No. Figure 3. Figure 4. Figure 5. Transmission Sensor Removal............................................................................................ 0120-3 Transmission Sensor Installation......................................................................................... 0120-4 Transmission Sensor Connector.......................................................................................... 0120-5

BOOM ANGLE SENSOR REPLACEMENT................................................................................................. WP 0121 Figure 1. Figure 2. Figure 3. Figure 4. Boom Angle Sensor Removal.............................................................................................. 0121-2 Boom Angle Sensor Removal.............................................................................................. 0121-3 Boom Angle Sensor Removal.............................................................................................. 0121-4 Boom Angle Sensor Installation........................................................................................... 0121-5

BOOM EXTENSION SENSOR REPLACEMENT........................................................................................ WP 0122 Figure 1. Figure 2. Figure 3. Figure 4. Boom Extension Sensor Removal........................................................................................ 0122-1 Boom Extension Sensor Removal........................................................................................ 0122-2 Boom Extension Sensor Removal........................................................................................ 0122-3 Boom Extension Sensor Installation..................................................................................... 0122-4

TOPHANDLER ANGLE SENSOR REPLACEMENT................................................................................... WP 0123 Figure 1. Figure 2. Figure 3. Figure 4. Figure 5. Figure 6. Figure 7. Figure 8. Tophandler Angle Sensor Removal..................................................................................... 0123-2 Tophandler Angle Sensor Removal..................................................................................... 0123-3 Tophandler Angle Sensor Removal..................................................................................... 0123-4 Tophandler Angle Sensor Removal..................................................................................... 0123-5 Tophandler Angle Sensor Installation.................................................................................. 0123-6 Tophandler Angle Sensor Installation.................................................................................. 0123-7 Tophandler Angle Sensor Installation.................................................................................. 0123-8 Tophandler Angle Sensor Installation.................................................................................. 0123-9

HYDRAULIC RESERVOIR AND LIFT CYLINDER SENSORS REPLACEMENT....................................... WP 0124 Figure 1. Figure 2. Figure 3. Temperature Sensor Replacement...................................................................................... 0124-2 Pressure Sensor Replacement............................................................................................ 0124-3 Lift Cylinder Sensor Replacement........................................................................................ 0124-4

STEERING SYSTEM WHEEL SENSOR REPLACEMENT......................................................................... WP 0125

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Page No. WP Sequence No. Figure 1. Figure 2. Figure 3. Figure 4. Table 1. Table 2. Figure 5. Figure 6. Steering System Wheel Sensor Removal............................................................................ 0125-2 Steering System Wheel Sensor Removal............................................................................ 0125-3 Steering System Wheel Sensor Removal............................................................................ 0125-4 Steering System Wheel Sensor Installation......................................................................... 0125-5 Rear Junction Box X167 Wire Connections......................................................................... 0125-6 Front Junction Box X192 Wire Connections......................................................................... 0125-6 Steering System Wheel Sensor Installation......................................................................... 0125-7 Steering System Wheel Sensor Installation......................................................................... 0125-8

SEAT WARNING BUZZER REPLACEMENT.............................................................................................. WP 0126 Figure 1. Figure 2. Figure 3. Figure 4. Seat Warning Buzzer Replacement..................................................................................... 0126-1 Seat Warning Buzzer Replacement..................................................................................... 0126-2 Seat Warning Buzzer Replacement..................................................................................... 0126-3 Seat Warning Buzzer Replacement..................................................................................... 0126-4

ELECTRIC HORN REPLACEMENT............................................................................................................ WP 0127 Figure 1. Electric Horn Replacement................................................................................................... 0127-2

BATTERY MAINTENANCE......................................................................................................................... WP 0128 Figure 1. Figure 2. Figure 3. Battery Replacement............................................................................................................ 0128-2 Battery Service..................................................................................................................... 0128-3 Battery Installation................................................................................................................ 0128-4

BATTERY CABLES REPLACEMENT......................................................................................................... WP 0129 Figure 1. Figure 2. Figure 3. Figure 4. Figure 5. Figure 6. Battery Cables Replacement................................................................................................ 0129-2 Solar Charger Disconnect.................................................................................................... 0129-2 Battery Cables Replacement................................................................................................ 0129-3 Battery Cables Replacement................................................................................................ 0129-4 Solar Charger Connection.................................................................................................... 0129-5 Battery Cables Replacement................................................................................................ 0129-5

MASTER BATTERY SWITCH REPLACEMENT......................................................................................... WP 0130

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Page No. WP Sequence No. Figure 1. Figure 2. Figure 3. Master Battery Switch Replacement.................................................................................... 0130-1 Master Battery Switch Replacement.................................................................................... 0130-2 Master Battery Switch Replacement.................................................................................... 0130-3

AMBIENT TEMPERATURE SENSOR REPLACEMENT............................................................................. WP 0131 Figure 1. Figure 2. Ambient Temperature Sensor Removal............................................................................... 0131-2 Ambient Temperature Sensor Installation............................................................................ 0131-3

FUEL LEVEL SENDING UNIT REPLACEMENT......................................................................................... WP 0132 Figure 1. Figure 2. Figure 3. Fuel Level Sending Unit Connector Removal...................................................................... 0132-1 Fuel Level Sending Unit Removal........................................................................................ 0132-2 Fuel Level Sending Unit Installation..................................................................................... 0132-3

BACKUP ALARM REPLACEMENT............................................................................................................. WP 0133 Figure 1. Figure 2. Backup Alarm Removal........................................................................................................ 0133-1 Backup Alarm Installation..................................................................................................... 0133-2

SLAVE STARTING RECEPTACLE REPLACEMENT................................................................................. WP 0134 Figure 1. Figure 2. Figure 3. Figure 4. Figure 5. Index Volume 2 Chapter 5 - MAINTENANCE INSTRUCTIONS TRANSMISSION ASSEMBLY MAINTENANCE.......................................................................................... WP 0135 Figure 1. Figure 2. Figure 3. Figure 4. Transmission Sensors Removal........................................................................................... 0135-3 Transmission Hoses Removal.............................................................................................. 0135-4 Transmission Oil Fill Tube Removal..................................................................................... 0135-5 Flywheel Housing Access Cover.......................................................................................... 0135-5 Right Slave Starting Receptacle Replacement.................................................................... 0134-1 Right Slave Starting Receptacle Replacement.................................................................... 0134-2 Right Slave Starting Receptacle Replacement.................................................................... 0134-3 Left Slave Starting Receptacle Replacement....................................................................... 0134-4 Left Slave Starting Receptacle Replacement....................................................................... 0134-5

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Page No. WP Sequence No. Figure 5. Figure 6. Figure 7. Figure 8. Figure 9. Figure 10. Figure 11. Figure 12. Figure 13. Figure 14. Figure 15. Figure 16. Figure 17. Figure 18. Figure 19. Flywheel-to-Damper Plate Access Cover Removal............................................................. 0135-6 Damper Plates-to-Flywheel Screw Removal........................................................................ 0135-7 Flywheel Housing Screws Removal..................................................................................... 0135-7 Transmission-to-Mounting Bracket Removal....................................................................... 0135-8 Electrical Connectors Removal............................................................................................ 0135-9 Transmission Sensors Installation...................................................................................... 0135-10 Transmission-to-Mounting Bracket Screws Installation...................................................... 0135-12 Flywheel-to-Damper Plate Screw Installation..................................................................... 0135-13 Flywheel Housing Screws Installation................................................................................ 0135-13 Transmission-to-Mounting Bracket Screws Installation...................................................... 0135-14 Flywheel Housing Access Cover Installation...................................................................... 0135-15 Flywheel-to-Damper Plate Access Cover Installation........................................................ 0135-15 Transmission Oil Fill Tube Installation................................................................................ 0135-16 Transmission Hoses Installation......................................................................................... 0135-17 Transmission Electrical Connectors................................................................................... 0135-18

TRANSMISSION CALIBRATION................................................................................................................. WP 0136 Figure 1. Figure 2. Table 1. Table 2. Calibration............................................................................................................................ 0136-2 Calibration............................................................................................................................ 0136-3 Main Transmission Calibration Codes.................................................................................. 0136-4 Sub Transmission Calibration Codes................................................................................... 0136-5

TRANSMISSION ASSEMBLY HYDRAULIC HOSES AND PIPES REPLACEMENT.................................. WP 0137 Figure 1. Figure 2. Transmission Assembly Hose and Pipe Location Diagram.................................................. 0137-2 Transmission Hose and Pipe Location................................................................................. 0137-3

TRANSMISSION OIL DIPSTICK HOSE AND PIPE REPLACEMENT........................................................ WP 0138 Figure 1. Transmission Oil Dipstick Hose and Pipe Replacement...................................................... 0138-3

TRANSMISSION TORQUE CONVERTER REPLACEMENT...................................................................... WP 0139 Figure 1. Damper Plates Removal...................................................................................................... 0139-1

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Page No. WP Sequence No. Figure 2. Torque Converter Removal.................................................................................................. 0139-3

TRANSMISSION OIL, OIL FILTERS, AND OIL FILTER HEAD MAINTENANCE....................................... WP 0140 Figure 1. Figure 2. Figure 3. Figure 4. Figure 5. Figure 6. Transmission Oil Draining and Filling................................................................................... 0140-3 Transmission Oil Filters Replacement.................................................................................. 0140-5 Transmission Oil Filter Head Replacement.......................................................................... 0140-6 Transmission Oil Filter Head Replacement.......................................................................... 0140-7 Transmission Internal Coarse Oil Filter Removal................................................................. 0140-8 Transmission Internal Coarse Oil Filter Installation............................................................ 0140-10

TRANSMISSION OIL COOLER REPLACEMENT....................................................................................... WP 0141 Figure 1. Figure 2. Figure 3. Figure 4. Figure 5. Figure 6. Figure 7. Transmission Oil Coolers Removal...................................................................................... 0141-2 Transmission Oil Coolers Removal...................................................................................... 0141-3 Transmission Oil Coolers Removal...................................................................................... 0141-4 Transmission Oil Coolers Removal...................................................................................... 0141-5 Transmission Oil Coolers Installation................................................................................... 0141-6 Transmission Oil Coolers Installation................................................................................... 0141-7 Transmission Oil Coolers Installation................................................................................... 0141-8

TRANSMISSION OIL FILTER HOSES AND OIL COOLER HOSES AND FITTINGS REPLACEMENT.......................................................................................................................................... WP 0142 Figure 1. Figure 2. Transmission-to-Oil Cooler Hoses Replacement................................................................. 0142-3 Transmission-to-Oil Filter Hose Replacement. .................................................................... 0142-5

FRONT AND REAR PROPELLER SHAFTS REPLACEMENT................................................................... WP 0143 Figure 1. Figure 2. Figure 3. Figure 4. Figure 5. Front Propeller Shaft Removal............................................................................................. 0143-2 Front Propeller Shaft Removal. ........................................................................................... 0143-3 Rear Propeller Shaft Removal.............................................................................................. 0143-4 Rear Propeller Shaft Removal.............................................................................................. 0143-5 Rear Propeller Shaft Installation. ......................................................................................... 0143-7

UNIVERSAL JOINT REPLACEMENT......................................................................................................... WP 0144 Figure 1. Propeller Shaft Universal Joint Replacement....................................................................... 0144-3

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Page No. WP Sequence No. FRONT AXLE ASSEMBLY REPLACEMENT.............................................................................................. WP 0145 Figure 1. Figure 2. Figure 3. Figure 4. Figure 5. Figure 6. Front Axle Removal.............................................................................................................. 0145-2 Front Axle Removal.............................................................................................................. 0145-3 Front Axle Removal.............................................................................................................. 0145-4 Front Axle Removal.............................................................................................................. 0145-5 Front Axle Removal.............................................................................................................. 0145-6 Front Axle Installation........................................................................................................... 0145-7

TRANSMISSION AND FRONT AND REAR AXLE VENT HOSES REPLACEMENT.................................. WP 0146 Figure 1. Figure 2. Figure 3. Figure 4. Figure 5. Front Axle Vent Hose Removal............................................................................................ 0146-2 Front Axle Vent Hose Replacement..................................................................................... 0146-3 Rear Axle Vent Hose Replacement...................................................................................... 0146-4 Rear Axle Vent Hose Replacement...................................................................................... 0146-5 Transmission Vent Hose Replacement................................................................................ 0146-7

REAR AXLE ASSEMBLY MAINTENANCE................................................................................................. WP 0147 Figure 1. Figure 2. Figure 3. Rear Axle Rigging................................................................................................................ 0147-2 Rear Axle Removal.............................................................................................................. 0147-3 Rear Axle Installation........................................................................................................... 0147-5

CAGING AND UNCAGING PARKING BRAKE........................................................................................... WP 0148 Figure 1. Figure 2. Figure 3. Caging Parking Brake.......................................................................................................... 0148-2 Caging Parking Brake.......................................................................................................... 0148-2 Caging Parking Brake.......................................................................................................... 0148-3

PARKING BRAKE CYLINDER REPLACEMENT........................................................................................ WP 0149 Figure 1. Figure 2. Figure 3. Figure 4. Parking Brake Cylinder Removal......................................................................................... 0149-3 Parking Brake Cylinder Installation...................................................................................... 0149-5 Parking Brake Rotor Removal.............................................................................................. 0149-7 Parking Brake Bracket Replacement................................................................................... 0149-9

PARKING BRAKE PADS MAINTENANCE.................................................................................................. WP 0150

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Page No. WP Sequence No. Figure 1. Parking Brake Pad Replacement. ....................................................................................... 0150-3

PARKING BRAKE CONTROL VALVE REPLACEMENT............................................................................ WP 0151 Figure 1. Figure 2. Figure 3. Parking Brake Control Valve Removal................................................................................. 0151-1 Parking Brake Control Valve Replacement.......................................................................... 0151-3 Parking Brake Control Valve Installation.............................................................................. 0151-4

PARKING BRAKE SYSTEM HYDRAULIC HOSES AND FITTINGS REPLACEMENT.............................. WP 0152 SERVICE BRAKE CONTROL VALVE REPLACEMENT............................................................................. WP 0153 Figure 1. Service Brake Control Valve Replacement.......................................................................... 0153-2

BRAKE ACCUMULATOR REPLACEMENT................................................................................................ WP 0154 Figure 1. Figure 2. Figure 3. Brake Accumulators and Valve Block Replacement............................................................ 0154-2 Brake Accumulators and Valve Block Replacement............................................................ 0154-3 Brake Accumulators and Valve Block Replacement............................................................ 0154-4

BRAKE AND STEERING ACCUMULATOR SERVICE............................................................................... WP 0155 Figure 1. Figure 2. Figure 3. Figure 4. Figure 5. Figure 6. Figure 7. Figure 8. Figure 9. Figure 10. Figure 11. Figure 12. Figure 13. Figure 14. Brake Accumulator Testing.................................................................................................. 0155-2 Brake Accumulator Testing.................................................................................................. 0155-3 Brake Accumulator Testing.................................................................................................. 0155-4 Brake Accumulator Testing.................................................................................................. 0155-5 Brake Accumulator Testing.................................................................................................. 0155-5 Brake Accumulator Charging............................................................................................... 0155-6 Brake Accumulator Charging............................................................................................... 0155-7 Brake Accumulator Charging............................................................................................... 0155-7 Brake Accumulator Charging............................................................................................... 0155-8 Brake Accumulator Charging............................................................................................... 0155-9 Brake Accumulator Charging............................................................................................... 0155-9 Brake Accumulator Charging............................................................................................. 0155-10 Brake Accumulator Charging............................................................................................. 0155-11 Brake Accumulator Testing................................................................................................ 0155-12

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Page No. WP Sequence No. Figure 15. Figure 16. Figure 17. Figure 18. Figure 19. Brake Accumulator Charging............................................................................................. 0155-12 Brake Accumulator Charging............................................................................................. 0155-13 Brake Accumulator Charging............................................................................................. 0155-13 Brake Accumulator Charging............................................................................................. 0155-14 Steering Accumulator Pre-charge Pressure Check............................................................ 0155-15

BRAKE SYSTEM CHARGING VALVE PRESSURE ADJUSTMENT.......................................................... WP 0156 Figure 1. Brake System Charging Valve Pressure Adjustment........................................................... 0156-3

SERVICE BRAKE SYSTEM HYDRAULIC HOSES AND FITTINGS REPLACEMENT............................... WP 0157 Figure 1. Service Brake System Hydraulic Hoses and Fittings Replacement..................................... 0157-3

BRAKE COOLING FILTER AND FILTER HEAD REPLACEMENT............................................................. WP 0158 Figure 1. Figure 2. Figure 3. Brake Cooling Filter Replacement........................................................................................ 0158-2 Brake Cooling Filter Head Removal..................................................................................... 0158-3 Brake Cooling Filter Head Installation.................................................................................. 0158-4

BRAKE LIGHT AND PRESSURE SWITCHES REPLACEMENT................................................................ WP 0159 Figure 1. Figure 2. Figure 3. Left Lower Panel Removal................................................................................................... 0159-2 Right Lower Panel Removal................................................................................................. 0159-2 Brake Light and Pressure Switch Replacement................................................................... 0159-3

STEERING COLUMN BASE AND BRAKE PEDAL MAINTENANCE.......................................................... WP 0160 Figure 1. Figure 2. Figure 3. Figure 4. Figure 5. Figure 6. Figure 7. Figure 8. Figure 9. Steering Column Base Removal.......................................................................................... 0160-1 Steering Column Base Removal.......................................................................................... 0160-2 Steering Column Base Removal.......................................................................................... 0160-2 Steering Column Base Disassembly.................................................................................... 0160-3 Steering Column Base Disassembly.................................................................................... 0160-4 Steering Column Base Disassembly.................................................................................... 0160-4 Steering Column Base Assembly......................................................................................... 0160-5 Steering Column Base Installation....................................................................................... 0160-6 Steering Column Base Installation....................................................................................... 0160-6

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Page No. WP Sequence No. Figure 10. Steering Column Base Installation....................................................................................... 0160-7

BRAKE INCHING SWITCH REPLACEMENT............................................................................................. WP 0161 Figure 1. Figure 2. Figure 3. Brake Inching Switch Removal............................................................................................. 0161-2 Brake Inching Switch Removal............................................................................................. 0161-3 Brake Inching Switch Installation.......................................................................................... 0161-4

WHEEL ASSEMBLY REPLACEMENT........................................................................................................ WP 0162 Figure 1. Figure 2. Figure 3. Figure 4. Figure 5. Raise Front Axle................................................................................................................... 0162-2 Raise Front Axle................................................................................................................... 0162-3 Raise Front Axle................................................................................................................... 0162-3 Raise Front Axle................................................................................................................... 0162-4 Wheel and Tire Replacement............................................................................................... 0162-5

BOGIE WHEELS AND TIRES MAINTENANCE.......................................................................................... WP 0163 Figure 1. Figure 2. Figure 3. Figure 4. Lower Bogie Wheel.............................................................................................................. 0163-1 Bogie Wheel Replacement................................................................................................... 0163-3 Screw Assembly Removal and Installation.......................................................................... 0163-5 Bogie Wheel Frame Replacement....................................................................................... 0163-7

DOLLY WHEELS AND TIRES MAINTENANCE.......................................................................................... WP 0164 Figure 1. Figure 2. Dolly Wheel Disassembly..................................................................................................... 0164-2 Dolly Wheel Assembly.......................................................................................................... 0164-3

STEERING WHEEL REPLACEMENT......................................................................................................... WP 0165 Figure 1. Figure 2. Figure 3. Steering Wheel Removal...................................................................................................... 0165-1 Steering Wheel Replacement............................................................................................... 0165-2 Steering Wheel Installation................................................................................................... 0165-3

STEERING COLUMN REPLACEMENT...................................................................................................... WP 0166 Figure 1. Figure 2. Figure 3. Steering Column Removal................................................................................................... 0166-1 Steering Column Removal................................................................................................... 0166-2 Steering Column Removal................................................................................................... 0166-3

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Page No. WP Sequence No. Figure 4. Figure 5. Figure 6. Figure 7. Figure 8. Figure 9. Figure 10. Steering Column Removal................................................................................................... 0166-3 Steering Column Removal................................................................................................... 0166-4 Steering Column Removal and Installation.......................................................................... 0166-5 Steering Column Installation................................................................................................ 0166-6 Steering Column Installation................................................................................................ 0166-7 Steering Column Installation................................................................................................ 0166-8 Steering Column Installation................................................................................................ 0166-9

STEERING COLUMN REPAIR.................................................................................................................... WP 0167 Figure 1. Steering Column Disassembly and Assembly...................................................................... 0167-3

STEERING SENSOR REPLACEMENT...................................................................................................... WP 0168 Figure 1. Figure 2. Figure 3. Figure 4. Figure 5. Figure 6. Steering Column Sensor Removal....................................................................................... 0168-1 Steering Column Sensor Removal....................................................................................... 0168-2 Steering Column Sensor Removal....................................................................................... 0168-3 Steering Column Sensor Installation.................................................................................... 0168-3 Steering Column Sensor Installation.................................................................................... 0168-4 Steering Column Sensor Installation.................................................................................... 0168-5

EMERGENCY STEERING PUMP REPLACEMENT................................................................................... WP 0169 Figure 1. Emergency Steering Pump Replacement............................................................................ 0169-3

STEERING SYSTEM HYDRAULIC HOSES AND FITTINGS REPLACEMENT......................................... WP 0170 FRONT AND REAR AXLE STEERING CYLINDERS REPLACEMENT...................................................... WP 0171 Figure 1. Front and Rear Steering Cylinder Replacement.................................................................. 0171-3

STEERING ACCUMULATOR REPLACEMENT.......................................................................................... WP 0172 Figure 1. Steering Accumulator Replacement..................................................................................... 0172-3

STEERING CONTROL VALVE REPLACEMENT....................................................................................... WP 0173 Figure 1. Figure 2. Steering Control Valve Removal.......................................................................................... 0173-3 Steering Control Valve Removal and Installation................................................................. 0173-5

STEERING CALIBRATION.......................................................................................................................... WP 0174

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Page No. WP Sequence No. TRANSMISSION SKID PLATE AND ACCESS COVERS REPLACEMENT............................................... WP 0175 Figure 1. Figure 2. Figure 3. Figure 4. Skid Plate Replacement....................................................................................................... 0175-3 Front Access Cover Replacement........................................................................................ 0175-4 Middle Access Cover and Cab Support Replacement......................................................... 0175-5 Rear Access Cover Replacement........................................................................................ 0175-6

BOOM SUPPORT MAINTENANCE............................................................................................................ WP 0176 Figure 1. Figure 2. Figure 3. Figure 4. Figure 5. Figure 6. Figure 7. Figure 8. Figure 9. Figure 10. Figure 11. Figure 12. Boom Support Removal....................................................................................................... 0176-2 Boom Support Removal....................................................................................................... 0176-3 Boom Support Removal....................................................................................................... 0176-3 Boom Support Removal....................................................................................................... 0176-4 Boom Support Removal....................................................................................................... 0176-5 Boom Support Removal....................................................................................................... 0176-6 Boom Support Installation.................................................................................................... 0176-7 Boom Support Installation.................................................................................................... 0176-8 Boom Support Installation.................................................................................................... 0176-9 Boom Support Installation.................................................................................................... 0176-9 Boom Support Installation.................................................................................................. 0176-10 Boom Support Installation.................................................................................................. 0176-11

FLEXIBLE CONVEYOR MAINTENANCE................................................................................................... WP 0177 Figure 1. Figure 2. Figure 3. Figure 4. Figure 5. Figure 6. Figure 7. Figure 8. Boom Wiring Harness and Cable Removal.......................................................................... 0177-2 Boom Wiring Harness and Cable Removal.......................................................................... 0177-3 Boom Wiring Harness and Cable Removal.......................................................................... 0177-3 Hydraulic Hoses Removal.................................................................................................... 0177-4 Conveyor Removal............................................................................................................... 0177-5 Conveyor Installation............................................................................................................ 0177-6 Hydraulic Hoses Installation................................................................................................. 0177-7 Wiring Harness and Cable Installation................................................................................. 0177-7

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Page No. WP Sequence No. Figure 9. Figure 10. Wiring Harness and Cable Installation................................................................................. 0177-8 Connect Cable and Wiring Harness..................................................................................... 0177-9

PINTLE HOOK MAINTENANCE.................................................................................................................. WP 0178 Figure 1. Tow Pintle Replacement...................................................................................................... 0178-2

CAB LIFT FRAME MAINTENANCE............................................................................................................ WP 0179 Figure 1. Figure 2. Figure 3. Figure 4. Figure 5. Figure 6. Figure 7. Figure 8. Figure 9. Figure 10. Figure 11. Figure 12. Figure 13. Figure 14. Figure 15. Figure 16. Figure 17. Figure 18. Figure 19. Figure 20. Figure 21. Figure 22. Cab Transport Lift System Inspection.................................................................................. 0179-2 Cab Transport Lift System Inspection.................................................................................. 0179-3 Cab Transport Lift System Inspection.................................................................................. 0179-3 Cab Transport Lift System Inspection.................................................................................. 0179-4 Cab Adjustment: Operational Position................................................................................. 0179-5 Cab Adjustment: Operational Position................................................................................. 0179-6 Cab Adjustment: Operational Position................................................................................. 0179-7 Cab Adjustment: Operational Position................................................................................. 0179-7 Cab Adjustment: Operational Position................................................................................. 0179-8 Cab Adjustment: Transport Position..................................................................................... 0179-9 Cab Adjustment: Transport Position................................................................................... 0179-10 Cab Adjustment: Transport Position................................................................................... 0179-11 Cab Adjustment: Transport Position................................................................................... 0179-12 Cab Transport Lift Removal............................................................................................... 0179-13 Cab Transport Lift Removal............................................................................................... 0179-14 Cab Transport Lift Removal............................................................................................... 0179-15 Cab Transport Lift Installation............................................................................................ 0179-16 Cab Transport Lift Installation............................................................................................ 0179-17 Cab Transport Lift Installation............................................................................................ 0179-18 Cab Transport Lift Structure Removal................................................................................ 0179-19 Cab Transport Lift Structure Removal................................................................................ 0179-20 Cab Transport Lift Structure Removal................................................................................ 0179-21

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Page No. WP Sequence No. Figure 23. Figure 24. Figure 25. Cab Transport Lift Structure Installation............................................................................. 0179-22 Cab Transport Lift Structure Installation............................................................................. 0179-23 Cab Transport Lift Structure Installation............................................................................. 0179-24

RIGHT-SIDE STEP ASSEMBLY REPLACEMENT..................................................................................... WP 0180 Figure 1. Right-Side Step Assembly Removal.................................................................................... 0180-2

LEFT-SIDE STAIR ASSEMBLY REPLACEMENT....................................................................................... WP 0181 Figure 1. Figure 2. Figure 3. Left-Side Step Assembly Replacement................................................................................ 0181-1 Left-Side Stair Assembly Removal....................................................................................... 0181-2 Left-Side Stair Assembly Replacement................................................................................ 0181-3

STORAGE COMPARTMENT DOORS AND LATCHES REPLACEMENT.................................................. WP 0182 Figure 1. Figure 2. Figure 3. Storage Compartment Door Removal.................................................................................. 0182-1 Storage Compartment Door Removal and Installation......................................................... 0182-2 Storage Compartment Door Installation............................................................................... 0182-3

BATTERY AND DOLLY WHEELS STORAGE COMPARTMENT REPLACEMENT................................... WP 0183 Figure 1. Battery and Dolly Wheels Storage Compartment Replacement.......................................... 0183-3

REMOTE HYDRAULIC CONTROL COMPARTMENT REPLACEMENT.................................................... WP 0184 Figure 1. Remote Hydraulic Control Compartment Replacement....................................................... 0184-2

ENGINE COVER MAINTENANCE.............................................................................................................. WP 0185 Figure 1. Figure 2. Figure 3. Figure 4. Figure 5. Engine Cover Removal........................................................................................................ 0185-1 Engine Cover Disassembly.................................................................................................. 0185-2 Engine Cover Disassembly.................................................................................................. 0185-2 Engine Cover Disassembly.................................................................................................. 0185-3 Engine Cover Assembly....................................................................................................... 0185-4

CAB DOOR ASSEMBLY MAINTENANCE.................................................................................................. WP 0186 Figure 1. Figure 2. Figure 3. Cab Door Assembly Removal.............................................................................................. 0186-1 Cab Door Assembly Removal.............................................................................................. 0186-2 Cab Door Disassembly......................................................................................................... 0186-3

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Page No. WP Sequence No. Figure 4. Figure 5. Figure 6. Figure 7. Cab Door Disassembly and Assembly................................................................................. 0186-4 Cab Door Installation............................................................................................................ 0186-5 Cab Door Installation............................................................................................................ 0186-6 Cab Door Installation............................................................................................................ 0186-7

CAB DOOR WEATHERSEAL REPLACEMENT.......................................................................................... WP 0187 Figure 1. Figure 2. Figure 3. Figure 4. Figure 5. Figure 6. Cab Door Weatherseal Removal.......................................................................................... 0187-1 Cab Door Weatherseal Removal.......................................................................................... 0187-2 Cab Door Weatherseal Removal.......................................................................................... 0187-3 Cab Door Weatherseal Installation....................................................................................... 0187-4 Cab Door Weatherseal Installation....................................................................................... 0187-5 Cab Door Weatherseal Installation....................................................................................... 0187-5

WINDSHIELD AND WINDOW GLASS REPLACEMENT............................................................................ WP 0188 Figure 1. Figure 2. Window Removal and Installation........................................................................................ 0188-3 Window Removal and Installation........................................................................................ 0188-4

MUDGUARD REPLACEMENT.................................................................................................................... WP 0189 Figure 1. Mudguard Replacement....................................................................................................... 0189-2

FENDER ASSEMBLY REPLACEMENT...................................................................................................... WP 0190 Figure 1. Figure 2. Figure 3. Figure 4. Figure 5. Figure 6. Figure 7. Figure 8. Figure 9. Fender and Fender Bracket Removal (RT 240V1)............................................................... 0190-2 Fender and Fender Bracket Replacement (RT 240V1)........................................................ 0190-3 Front Fender and Fender Bracket Removal (RT 240V1R)................................................... 0190-4 Front Fender and Fender Bracket Replacement (RT 240V1R)............................................ 0190-5 Rear Fender and Fender Bracket Removal (RT 240V2 and RT 240V3).............................. 0190-6 Rear Fender and Fender Bracket Replacement (RT 240V2 and RT 240V3)....................... 0190-7 Front Fender and Fender Bracket Removal (RT 240V2 and RT 240V3)............................. 0190-8 Front Fender and Fender Bracket Replacement (RT 240V2 and RT 240V3)...................... 0190-9 Front Bracket Mounting Plate Replacement....................................................................... 0190-10

SEAT ASSEMBLY MAINTENANCE............................................................................................................ WP 0191

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Page No. WP Sequence No. Figure 1. Figure 2. Figure 3. Figure 4. Figure 5. Seat Removal....................................................................................................................... 0191-2 Seat Disassembly................................................................................................................. 0191-3 Seat Disassembly and Assembly......................................................................................... 0191-5 Seat Assembly..................................................................................................................... 0191-7 Seat Installation.................................................................................................................... 0191-8

SEAT BELT REPLACEMENT...................................................................................................................... WP 0192 Figure 1. Seatbelt Replacement.......................................................................................................... 0192-2

REARVIEW MIRRORS REPLACEMENT.................................................................................................... WP 0193 Figure 1. Figure 2. Figure 3. Interior Rearview Mirror Replacement.................................................................................. 0193-1 Exterior Rearview Mirror Removal....................................................................................... 0193-2 Exterior Rearview Mirror Removal and Installation.............................................................. 0193-3

WINDSHIELD WIPER MAINTENANCE...................................................................................................... WP 0194 Figure 1. Figure 2. Figure 3. Figure 4. Figure 5. Figure 6. Figure 7. Figure 8. Figure 9. Figure 10. Figure 11. Figure 12. Figure 13. Figure 14. Figure 15. Front Windshield Wiper and Motor Removal........................................................................ 0194-2 Front Windshield Wiper and Motor Removal........................................................................ 0194-3 Front Windshield Wiper and Motor Removal........................................................................ 0194-3 Front Windshield Wiper and Motor Installation..................................................................... 0194-4 Front Windshield Wiper and Motor Installation..................................................................... 0194-5 Front Windshield Wiper and Motor Installation..................................................................... 0194-6 Rear Windshield Wiper and Motor Removal........................................................................ 0194-7 Rear Windshield Wiper and Motor Removal........................................................................ 0194-7 Rear Windshield Wiper and Motor Removal and Installation............................................... 0194-9 Rear Windshield Wiper and Motor Installation..................................................................... 0194-9 Roof Window Windshield Wiper and Motor Removal......................................................... 0194-10 Roof Window Windshield Wiper and Motor Removal......................................................... 0194-11 Roof Window Windshield Wiper and Motor Removal and Installation............................... 0194-12 Roof Window Windshield Wiper and Motor Installation...................................................... 0194-13 Roof Window Windshield Wiper and Motor Installation...................................................... 0194-14

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Page No. WP Sequence No. WINDSHIELD WASHER RESERVOIR AND PUMP REPLACEMENT....................................................... WP 0195 Figure 1. Figure 2. Figure 3. Figure 4. Windshield Washer Reservoir Replacement........................................................................ 0195-3 Windshield Washer Pump Removal..................................................................................... 0195-4 Windshield Washer Pump Replacement.............................................................................. 0195-5 Windshield Washer Pump Installation.................................................................................. 0195-6

HEATER HOSES REPLACEMENT............................................................................................................. WP 0196 Figure 1. Figure 2. Figure 3. Figure 4. Figure 5. Figure 6. Figure 7. Figure 8. Figure 9. Figure 10. Figure 11. Figure 12. Figure 13. Figure 14. Figure 15. Figure 16. Figure 17. Figure 18. Figure 19. Engine Heater Hoses Removal............................................................................................ 0196-2 Engine Heater Hoses Removal............................................................................................ 0196-3 Engine Heater Hoses Removal............................................................................................ 0196-3 Engine Heater Hoses Removal............................................................................................ 0196-4 Engine Heater Hoses Removal............................................................................................ 0196-5 Engine Heater Hoses Removal............................................................................................ 0196-5 Engine.................................................................................................................................. 0196-6 Engine Heater Hoses Removal............................................................................................ 0196-7 Cab Heater Hoses Removal RT 240V1 and RT 240V1R.................................................. 0196-8 Cab Heater Hoses Removal RT 240V2 and RT 240V3 Vehicles...................................... 0196-8 Cab Heater Hoses Removal................................................................................................. 0196-9 Cab Heater Hoses Removal............................................................................................... 0196-10 Cab Heater Hoses Removal............................................................................................... 0196-10 Cab Heater Hoses Removal............................................................................................... 0196-11 Cab Heater Hoses Installation............................................................................................ 0196-12 Cab Heater Hoses Installation............................................................................................ 0196-13 Cab Heater Hoses Installation............................................................................................ 0196-13 Cab Heater Hoses Installation RT 240V1 and RT 240V1R Vehicles.............................. 0196-14 Cab Heater Hoses Installation RT 240V2 and RT 240V3 Vehicles................................. 0196-14

CAB HEATER/AIR CONDITIONING UNIT MAINTENANCE....................................................................... WP 0197 Figure 1. Cab Heater/Air Conditioning Unit Removal.......................................................................... 0197-2

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Page No. WP Sequence No. Figure 2. Figure 3. Figure 4. Figure 5. Cab Heater/Air Conditioning Unit Removal.......................................................................... 0197-3 Cab Heater/Air Conditioning Unit Removal.......................................................................... 0197-4 Cab Heater/Air Conditioning Unit Removal.......................................................................... 0197-5 Cab Heater/Air Conditioning Unit Installation....................................................................... 0197-6

CAB HEATER/AIR CONDITIONING BLOWER MOTOR AND FAN REPLACEMENT................................ WP 0198 Figure 1. Figure 2. Figure 3. Figure 4. Front Panel Removal............................................................................................................ 0198-1 Cover Removal..................................................................................................................... 0198-2 Blower Motor and Fan Replacement.................................................................................... 0198-3 Blower Motor and Fan Installation........................................................................................ 0198-4

CAB AIR FILTERS REPLACEMENT........................................................................................................... WP 0199 Figure 1. Figure 2. Figure 3. Figure 4. Figure 5. Figure 6. Figure 7. Figure 8. Cab Grille Removal.............................................................................................................. 0199-2 Cab Side Air Filter Removal................................................................................................. 0199-3 Cab Side Air Filter Installation.............................................................................................. 0199-4 Left Lower Panel Removal RT 240V1 and RT 240V1R Vehicles Only............................. 0199-5 Cab Interior Air Filter Removal............................................................................................. 0199-5 Cab Interior Air Filter Removal............................................................................................. 0199-6 Left Lower Panel Installation RT 240V1 and RT 240V1R Vehicles Only.......................... 0199-7 Cab Interior Air Filter Installation.......................................................................................... 0199-8

CAB AUXILIARY FAN REPLACEMENT...................................................................................................... WP 0200 Figure 1. Figure 2. Figure 3. Access Panel Removal........................................................................................................ 0200-1 Auxiliary Fan Replacement.................................................................................................. 0200-2 Access Cover Installation..................................................................................................... 0200-3

AUTOLUBE SYSTEM MAINTENANCE....................................................................................................... WP 0201 Figure 1. Figure 2. Figure 3. Autolube Tube Replacement................................................................................................ 0201-2 Autolube Pump Replacement............................................................................................... 0201-3 Autolube Distribution Valve Replacement............................................................................ 0201-4

FIRE EXTINGUISHER BRACKET REPLACEMENT................................................................................... WP 0202

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Page No. WP Sequence No. Figure 1. Fire Extinguisher Bracket Replacement............................................................................... 0202-1

DATA PLATE REPLACEMENT................................................................................................................... WP 0203 Figure 1. Data Plate Replacement...................................................................................................... 0203-2

RELIEVING HYDRAULIC SYSTEM PRESSURE....................................................................................... WP 0204 Figure 1. Figure 2. Figure 3. Steering Accumulator Evacuation Valve.............................................................................. 0204-2 Steering Accumulator Evacuation Valves............................................................................ 0204-3 Float Control and Emergency Control Valves...................................................................... 0204-3

BOOM AND BRAKE SYSTEM HYDRAULIC PUMP REPLACEMENT....................................................... WP 0205 Figure 1. Figure 2. Pump Replacement.............................................................................................................. 0205-3 Pump Installation.................................................................................................................. 0205-5

COOLING FAN HYDRAULIC PUMP REPLACEMENT............................................................................... WP 0206 Figure 1. Figure 2. Pump Removal..................................................................................................................... 0206-3 Pump Installation.................................................................................................................. 0206-5

SERVO CONTROL VALVE REPLACEMENT............................................................................................. WP 0207 Figure 1. Servo Control Valve Replacement....................................................................................... 0207-3

HYDRAULIC SYSTEM COOLING HOSES AND FITTINGS REPLACEMENT........................................... WP 0208 AUXILIARY HYDRAULIC PUMP REPLACEMENT..................................................................................... WP 0209 Figure 1. Figure 2. Figure 3. Figure 4. Figure 5. Figure 6. Figure 7. Figure 8. Cover Removal..................................................................................................................... 0209-2 Hose and Wire Disconnects................................................................................................. 0209-3 Ground Strap and Power Cable Disconnects....................................................................... 0209-3 Pump Removal..................................................................................................................... 0209-4 Pump Installation.................................................................................................................. 0209-5 Ground Strap and Power Cable Connections...................................................................... 0209-5 Hose and Wire Connections................................................................................................. 0209-6 Cover Installation.................................................................................................................. 0209-7

TOPHANDLER HYDRAULIC SLEWING MOTORS MAINTENANCE......................................................... WP 0210 Figure 1. Turning Plate Cover Removal.............................................................................................. 0210-2

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Page No. WP Sequence No. Figure 2. Figure 3. Figure 4. Figure 5. Figure 6. Figure 7. Figure 8. Hydraulic Manifold and Hose Removal................................................................................ 0210-3 Hydraulic Manifold and Hose Removal................................................................................ 0210-3 Slewing Motor and Pinion Gear Removal............................................................................ 0210-5 Slewing Motor and Hydraulic Manifold Installation............................................................... 0210-6 Secure Hydraulic Manifold................................................................................................... 0210-7 Hoses and Fittings Installation and Connection................................................................... 0210-8 Protective Cover Installation................................................................................................. 0210-9

SLEWING MOTOR BRAKE REPLACEMENT............................................................................................. WP 0211 Figure 1. Figure 2. Figure 3. Spur Gear Removal.............................................................................................................. 0211-1 Slewing Motor Brake Removal and Replacement................................................................ 0211-3 Slewing Motor Gear Replacement....................................................................................... 0211-4

TOPHANDLER AND STEERING HYDRAULIC PUMP ASSEMBLY REPLACEMENT............................... WP 0212 Figure 1. Figure 2. Figure 3. Figure 4. Figure 5. Figure 6. Figure 7. Figure 8. Figure 9. Figure 10. Figure 11. Figure 12. Figure 13. Figure 14. Figure 15. Pump Removal..................................................................................................................... 0212-2 Pump Removal..................................................................................................................... 0212-3 Pump Removal..................................................................................................................... 0212-3 Pump Removal..................................................................................................................... 0212-4 Pump Removal..................................................................................................................... 0212-4 Pump Removal..................................................................................................................... 0212-5 Pump Removal..................................................................................................................... 0212-6 Pump Removal..................................................................................................................... 0212-7 Pump Removal..................................................................................................................... 0212-7 Pump Removal..................................................................................................................... 0212-8 Pump Removal..................................................................................................................... 0212-9 Pump Installation................................................................................................................ 0212-10 Pump Installation................................................................................................................ 0212-11 Pump Installation................................................................................................................ 0212-11 Pump Installation................................................................................................................ 0212-12

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Page No. WP Sequence No. Figure 16. Figure 17. Figure 18. Figure 19. Figure 20. Figure 21. Figure 22. Pump Installation................................................................................................................ 0212-13 Pump Installation................................................................................................................ 0212-14 Pump Installation................................................................................................................ 0212-14 Pump Installation................................................................................................................ 0212-15 Pump Installation................................................................................................................ 0212-16 Pump Installation................................................................................................................ 0212-17 Pump Installation................................................................................................................ 0212-18

TOPHANDLER AND STEERING HYDRAULIC PUMPS ADJUSTMENT.................................................... WP 0213 Figure 1. Figure 2. Figure 3. Figure 4. Figure 5. Figure 6. Tophandler Pump Hydraulic Pressure Adjustment.............................................................. 0213-2 Tophandler Pump Hydraulic Pressure Adjustment.............................................................. 0213-3 Tophandler Pump Hydraulic Pressure Adjustment.............................................................. 0213-4 Steering Pumps No. 1 and No. 2 Hydraulic Pressure Adjustment....................................... 0213-5 Steering Pumps No. 1 and No. 2 Hydraulic Pressure Adjustment....................................... 0213-6 Steering Pumps No. 1 and No. 2 Hydraulic Pressure Adjustment....................................... 0213-7

MAIN CONTROL VALVE REPLACEMENT................................................................................................. WP 0214 Figure 1. Figure 2. Figure 3. Figure 4. Figure 5. Main Control Valve Removal................................................................................................ 0214-2 Main Control Valve Removal................................................................................................ 0214-3 Main Control Valve Removal................................................................................................ 0214-5 Main Control Valve Installation............................................................................................. 0214-6 Main Control Valve Installation............................................................................................. 0214-7

BOOM FOLDING CONTROL VALVE REPLACEMENT.............................................................................. WP 0215 Figure 1. Boom Folding Control Valve Replacement.......................................................................... 0215-3

CAB TRANSPORT CONTROL VALVE REPLACEMENT........................................................................... WP 0216 Figure 1. Cab Transport Control Valve Replacement.......................................................................... 0216-3

CONTROL VALVE SOLENOIDS REPLACEMENT..................................................................................... WP 0217 Figure 1. Figure 2. Control Valve Solenoid Replacement Type A................................................................... 0217-3 Control Valve Solenoid Replacement Type B................................................................... 0217-4

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Page No. WP Sequence No. Figure 3. Figure 4. Control Valve Solenoid Replacement Type C................................................................... 0217-5 Control Valve Solenoid Replacement Type D................................................................... 0217-6

BOOM FOLDING CYLINDERS REPLACEMENT....................................................................................... WP 0218 Figure 1. Figure 2. Figure 3. Figure 4. Figure 5. Figure 6. Boom Folding Cylinder Replacement................................................................................... 0218-3 Boom Folding Cylinder Installation....................................................................................... 0218-4 Boom Folding Cylinder installation....................................................................................... 0218-5 Boom Folding Cylinder Installation....................................................................................... 0218-6 Boom Folding Cylinder Installation....................................................................................... 0218-7 Boom Folding Cylinder Installation....................................................................................... 0218-8

CAB PARKING AND SERVICE BRAKE HYDRAULIC HOSES AND FITTINGS REPLACEMENT.......................................................................................................................................... WP 0219 MAIN HYDRAULIC SYSTEM HOSES AND FITTINGS REPLACEMENT................................................... WP 0220 HYDRAULIC SERVO SYSTEM HOSES AND FITTINGS REPLACEMENT............................................... WP 0221 HYDRAULIC SYSTEM TEST POINT HOSES AND FITTINGS REPLACEMENT....................................... WP 0222 CAB TRANSPORT HYDRAULIC HOSES AND FITTINGS REPLACEMENT............................................. WP 0223 BOOM HYDRAULIC SYSTEM HOSES AND FITTINGS REPLACEMENT................................................. WP 0224 TOPHANDLER HYDRAULIC SYSTEM HOSES AND FITTINGS REPLACEMENT................................... WP 0225 FORKLIFT KIT HYDRAULIC HOSES AND FITTINGS REPLACEMENT.................................................... WP 0226 HYDRAULIC SYSTEM OIL FILTERS REPLACEMENT.............................................................................. WP 0227 Figure 1. Figure 2. Figure 3. Figure 4. Hydraulic Reservoir Return Oil Filter Removal..................................................................... 0227-2 Reservoir Return Oil Filter Installation.................................................................................. 0227-3 Hydraulic Reservoir Breather Filter Installation.................................................................... 0227-4 Hydraulic System In-Line Filters and Filter Head Replacement........................................... 0227-5

HYDRAULIC SYSTEM VALVE MAINTENANCE......................................................................................... WP 0228 Figure 1. Figure 2. Figure 3. Figure 4. Pump Shut-Off Valve Removal............................................................................................ 0228-3 Shift Valve Removal............................................................................................................. 0228-5 Boom Support/Bogie Supply Valve Removal....................................................................... 0228-6 Boom Support/Bogie Supply Valve Installation.................................................................... 0228-7

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Page No. WP Sequence No. Figure 5. Figure 6. Figure 7. Figure 8. Figure 9. Figure 10. Figure 11. Figure 12. Figure 13. Figure 14. Figure 15. Figure 16. Figure 17. Figure 18. Figure 19. Figure 20. Figure 21. Figure 22. Figure 23. Figure 24. Figure 25. Servo Pressure Regulator Valve Removal........................................................................... 0228-9 Bogie/Boom Support Flow Control Valve Removal............................................................ 0228-11 Boom Support Locking Pin Check Valve Removal............................................................ 0228-12 Boom Support Locking Pin Check Valve Installation......................................................... 0228-13 Bogie Pressure Ball Valve Removal................................................................................... 0228-15 Extension Cylinder Over-Center Valve Replacement........................................................ 0228-17 Parking Brake Hold Flow Control Valve Removal.............................................................. 0228-18 Parking Brake Hold Flow Control Valve Installation........................................................... 0228-19 Brake Charging Valve Replacement.................................................................................. 0228-21 Brake Drain Shut-Off Valve Replacement.......................................................................... 0228-23 Brake Circuit Safety Regulating Valve Replacement......................................................... 0228-25 Front Brake Cooling Bypass Valve Replacement.............................................................. 0228-27 Rear Brake Cooling Bypass Valve Replacement............................................................... 0228-29 Cooling Fan Control Valve Removal.................................................................................. 0228-30 Emergency Steering Pressure Balancing Valve Removal................................................. 0228-33 Moderation and Tilt Manifold Valve Removal..................................................................... 0228-34 Tilt Over-Center Valve Removal......................................................................................... 0228-36 Tilt Over-Center Installation................................................................................................ 0228-37 Oscillation Over-Center Valve Installation.......................................................................... 0228-39 Oscillation Float Lock Flow Control Valve Removal........................................................... 0228-40 Twistlock Double Pilot Operated Check Valve Removal.................................................... 0228-42

LIFT CYLINDER CONTROL VALVE REPLACEMENT............................................................................... WP 0229 Figure 1. Lift Cylinder Control Valve Replacement.............................................................................. 0229-3

TOPHANDLER CONTROL VALVES REPLACEMENT............................................................................... WP 0230 Figure 1. Tophandler Control Valve Replacement.............................................................................. 0230-3

BOOM LIFT CYLINDER REPLACEMENT.................................................................................................. WP 0231 Figure 1. Boom Lift Cylinder Removal................................................................................................. 0231-2

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Page No. WP Sequence No. Figure 2. Figure 3. Figure 4. Figure 5. Figure 6. Figure 7. Boom Lift Cylinder Removal................................................................................................. 0231-3 Boom Lift Cylinder Removal................................................................................................. 0231-4 Boom Lift Cylinder Removal................................................................................................. 0231-5 Boom Lift Cylinder Installation.............................................................................................. 0231-6 Boom Lift Cylinder Installation.............................................................................................. 0231-7 Boom Lift Cylinder Installation.............................................................................................. 0231-7

CAB LIFTING CYLINDER REPLACEMENT................................................................................................ WP 0232 Figure 1. Cab Lifting Cylinder Replacement........................................................................................ 0232-3

CAB SLIDING CYLINDER REPLACEMENT............................................................................................... WP 0233 Figure 1. Cab Sliding Cylinder Replacement....................................................................................... 0233-2

BOGIE WHEEL LIFT CYLINDERS REPLACEMENT.................................................................................. WP 0234 Figure 1. Figure 2. Figure 3. Figure 4. Hydraulic Cylinders Replacement........................................................................................ 0234-3 Hydraulic Cylinders Replacement........................................................................................ 0234-3 Hydraulic Cylinders Replacement........................................................................................ 0234-4 Hydraulic Cylinders Replacement........................................................................................ 0234-5

BOOM SUPPORT LOCKING PIN CYLINDER AND LOCKING PIN REPLACEMENT............................... WP 0235 Figure 1. Figure 2. Figure 3. Figure 4. Figure 5. Figure 6. Locking Pin Cylinder Removal............................................................................................. 0235-2 Locking Pin Cylinder Removal............................................................................................. 0235-3 Locking Pin Cylinder Removal............................................................................................. 0235-4 Locking Pin Cylinder Installation.......................................................................................... 0235-5 Locking Pin Cylinder Installation.......................................................................................... 0235-6 Locking Pin Cylinder Installation.......................................................................................... 0235-7

LOCKING PIN BUSHING REPLACEMENT................................................................................................ WP 0236 Figure 1. Figure 2. Figure 3. Figure 4. Frame Bushings Removal.................................................................................................... 0236-2 Frame Bushings Installation................................................................................................. 0236-3 Boom Support Bushings Removal....................................................................................... 0236-4 Boom Support Bushings Removal....................................................................................... 0236-5

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Page No. WP Sequence No. Figure 5. Figure 6. Figure 7. Boom Support Bushings Installation.................................................................................... 0236-6 Boom Support Bushings Installation.................................................................................... 0236-7 Boom Support Bushings Installation.................................................................................... 0236-8

TOPHANDLER TILT CYLINDERS REPLACEMENT.................................................................................. WP 0237 Figure 1. Tophandler Tilt Cylinder Replacement................................................................................. 0237-3

TOPHANDLER SIDESHIFT CYLINDERS REPLACEMENT....................................................................... WP 0238 Figure 1. Tophandler Sideshift Cylinder Replacement........................................................................ 0238-3

TOPHANDLER LEVELING CYLINDERS REPLACEMENT........................................................................ WP 0239 Figure 1. Tophandler Leveling Cylinder Removal............................................................................... 0239-3

TOPHANDLER TWISTLOCK CYLINDERS REPLACEMENT..................................................................... WP 0240 Figure 1. Tophandler Twistlock Cylinder Replacement....................................................................... 0240-3

TOPHANDLER TWISTLOCK REPLACEMENT.......................................................................................... WP 0241 Figure 1. Figure 2. Tophandler Twistlock Removal............................................................................................ 0241-2 Tophandler Twistlock Replacement..................................................................................... 0241-3

DRAINING AND FILLING HYDRAULIC RESERVOIR................................................................................ WP 0242 Figure 1. Figure 2. Draining Hydraulic Reservoir................................................................................................ 0242-2 Filling Hydraulic Reservoir.................................................................................................... 0242-3

HYDRAULIC RESERVOIR MAINTENANCE............................................................................................... WP 0243 Figure 1. Figure 2. Figure 3. Figure 4. Figure 5. Figure 6. Figure 7. Figure 8. Figure 9. Hydraulic Reservoir Removal............................................................................................... 0243-3 Hydraulic Reservoir Removal............................................................................................... 0243-3 Hydraulic Reservoir Removal............................................................................................... 0243-4 Hydraulic Reservoir Removal............................................................................................... 0243-5 Hydraulic Reservoir Removal............................................................................................... 0243-6 Hydraulic Reservoir Removal............................................................................................... 0243-7 Hydraulic Reservoir Removal............................................................................................... 0243-7 Hydraulic Reservoir Removal............................................................................................... 0243-8 Hydraulic Reservoir Installation............................................................................................ 0243-9

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Page No. WP Sequence No. Figure 10. Figure 11. Figure 12. Figure 13. Figure 14. Figure 15. Figure 16. Figure 17. Hydraulic Reservoir Installation............................................................................................ 0243-9 Hydraulic Reservoir Installation.......................................................................................... 0243-10 Hydraulic Reservoir Installation.......................................................................................... 0243-10 Hydraulic Reservoir Installation.......................................................................................... 0243-11 Hydraulic Reservoir Installation.......................................................................................... 0243-12 Hydraulic Reservoir Installation.......................................................................................... 0243-13 Hydraulic Reservoir Installation.......................................................................................... 0243-13 Hydraulic Reservoir Installation.......................................................................................... 0243-14

HYDRAULIC RESERVOIR SIGHT GAUGE REPLACEMENT.................................................................... WP 0244 Figure 1. Figure 2. Hydraulic Reservoir Sight Gauge Removal.......................................................................... 0244-1 Hydraulic Reservoir Sight Gauge Installation....................................................................... 0244-2

HYDRAULIC SYSTEM TEST POINT PROCEDURES................................................................................ WP 0245 Figure 1. Figure 2. Figure 3. Figure 4. Hydraulic System Test Points.............................................................................................. 0245-2 System Drain Valves............................................................................................................ 0245-3 Steering Accumulator Drain Valve....................................................................................... 0245-4 Engine Driven Pump Test Point........................................................................................... 0245-7

FORKLIFT CYLINDERS REPLACEMENT.................................................................................................. WP 0246 Figure 1. Forklift Cylinder Replacement.............................................................................................. 0246-3

RIFLE MOUNTING BRACKET REPLACEMENT........................................................................................ WP 0247 Figure 1. Figure 2. Figure 3. Rifle Mounting Bracket Removal.......................................................................................... 0247-1 Rifle Mounting Bracket Replacement................................................................................... 0247-2 Rifle Mounting Bracket Installation....................................................................................... 0247-3

AIR CONDITIONING SYSTEM MAINTENANCE........................................................................................ WP 0248 Figure 1. Figure 2. System Recovery................................................................................................................. 0248-3 Nitrogen Purging.................................................................................................................. 0248-5

AIR CONDITIONER LEAK TEST................................................................................................................ WP 0249 AIR CONDITIONING COMPRESSOR REPLACEMENT............................................................................ WP 0250

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Page No. WP Sequence No. Figure 1. Figure 2. Figure 3. Air Conditioner Compressor Removal.................................................................................. 0250-2 Air Conditioner Compressor Replacement........................................................................... 0250-3 Air Conditioner Compressor Installation............................................................................... 0250-4

AIR CONDITIONING COMPRESSOR DRIVE BELTS REPLACEMENT.................................................... WP 0251 Figure 1. Drive Belts Replacement...................................................................................................... 0251-3

AIR CONDITIONER HOSES REPLACEMENT........................................................................................... WP 0252 Figure 1. Figure 2. Figure 3. Figure 4. Figure 5. Figure 6. Figure 7. Figure 8. Figure 9. Figure 10. Figure 11. Figure 12. Figure 13. Figure 14. Figure 15. Figure 16. Figure 17. Chassis A/C Hoses Removal............................................................................................... 0252-1 Chassis A/C Hoses Removal and Installation...................................................................... 0252-2 Chassis A/C Hoses Removal Replacement......................................................................... 0252-3 Chassis A/C Hoses Installation............................................................................................ 0252-3 Cab Rear A/C Hose Removal.............................................................................................. 0252-4 Cab Rear A/C Hose Removal.............................................................................................. 0252-5 Cab Rear A/C Hose Replacement....................................................................................... 0252-6 Cab Rear A/C Hose Installation........................................................................................... 0252-7 Cab Interior A/C Hoses Removal......................................................................................... 0252-8 Cab Interior A/C Hoses Removal......................................................................................... 0252-9 Cab Interior A/C Hoses Removal......................................................................................... 0252-9 Cab Interior A/C Hoses Removal....................................................................................... 0252-10 Cab Interior A/C Hoses Removal....................................................................................... 0252-11 Cab Interior A/C Hoses Replacement................................................................................ 0252-12 Cab Interior A/C Hoses Installation.................................................................................... 0252-13 Cab Interior A/C Hoses Installation.................................................................................... 0252-14 Cab Interior A/C Hoses Installation.................................................................................... 0252-15

AIR CONDITIONER CONDENSER REPLACEMENT................................................................................. WP 0253 Figure 1. Figure 2. Figure 3. Air Conditioner Condenser Removal.................................................................................... 0253-1 Air Conditioner Condenser Removal.................................................................................... 0253-2 Air Conditioner Condenser Replacement............................................................................. 0253-3

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Page No. WP Sequence No. Figure 4. Air Conditioner Condenser Installation................................................................................. 0253-4

AIR CONDITIONER RECEIVER/DRYER REPLACEMENT........................................................................ WP 0254 Figure 1. Figure 2. Figure 3. Air Conditioner Receiver/Dryer Removal............................................................................. 0254-1 Air Conditioner Receiver/Dryer Replacement...................................................................... 0254-2 Air Conditioner Receiver/Dryer Installation.......................................................................... 0254-3

AIR CONDITIONER FANS MAINTENANCE............................................................................................... WP 0255 Figure 1. Figure 2. Figure 3. Figure 4. Figure 5. Figure 6. Condenser Fan Box Cover Removal.................................................................................... 0255-1 Air Conditioner Fan Replacement........................................................................................ 0255-2 Condenser Fan Box Cover................................................................................................... 0255-3 Relays Replacement............................................................................................................ 0255-4 Resistors Replacement........................................................................................................ 0255-5 Condenser Fan Box Cover Installation................................................................................. 0255-6

BOOM ASSEMBLY REPLACEMENT.......................................................................................................... WP 0256 Figure 1. Figure 2. Figure 3. Figure 4. Boom Assembly Removal.................................................................................................... 0256-2 Boom Assembly Removal.................................................................................................... 0256-3 Boom Assembly Installation................................................................................................. 0256-6 Boom Assembly Installation................................................................................................. 0256-7

BOOM AND TOPHANDLER CALIBRATION............................................................................................... WP 0257 Table 1. Figure 1. Table 2. Figure 2. Table 3. Figure 3. Table 4. Figure 4. Table 5. Range 600-800..................................................................................................................... 0257-2 Boom and Tophandler Calibration........................................................................................ 0257-2 Range 200-400..................................................................................................................... 0257-2 Boom and Tophandler Calibration........................................................................................ 0257-2 Range 200-400..................................................................................................................... 0257-3 Boom and Tophandler Calibration........................................................................................ 0257-3 Range 600-800..................................................................................................................... 0257-4 Boom and Tophandler Calibration........................................................................................ 0257-4 Range 35-150....................................................................................................................... 0257-5

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TABLE OF CONTENTS - Continued


Page No. WP Sequence No. Figure 5. Table 6. Figure 6. Table 7. Figure 7. Table 8. Figure 8. Table 9. Table 10. Boom and Tophandler Calibration........................................................................................ 0257-5 Range 400-550..................................................................................................................... 0257-6 Boom and Tophandler Calibration........................................................................................ 0257-6 Range 500-650..................................................................................................................... 0257-7 Boom and Tophandler Calibration........................................................................................ 0257-7 Range 800-950..................................................................................................................... 0257-8 Boom and Tophandler Calibration........................................................................................ 0257-8 Load Check.......................................................................................................................... 0257-8 Boom Calibration Completed............................................................................................... 0257-9

BOOM ASSEMBLY WEAR PLATES (SLIDE PLATE) REPLACEMENT..................................................... WP 0258 Figure 1. Figure 2. Figure 3. Figure 4. Figure 5. Figure 6. Figure 7. Figure 8. Figure 9. Figure 10. Figure 11. Figure 12. Figure 13. Figure 14. Figure 15. Figure 16. Figure 17. Boom Wear Plates Locations............................................................................................... 0258-2 Style A Wear Plate Removal................................................................................................ 0258-3 Style A Wear Plate Removal................................................................................................ 0258-4 Style A Wear Plate Installation............................................................................................. 0258-5 Style A Wear Plate Installation............................................................................................. 0258-6 Style B Wear Plate Removal................................................................................................ 0258-7 Style B Wear Plate Removal................................................................................................ 0258-8 Style B Wear Plate Removal................................................................................................ 0258-9 Style B Wear Plate Removal.............................................................................................. 0258-10 Style B Wear Plate Removal.............................................................................................. 0258-11 Style B Wear Plate Installation........................................................................................... 0258-12 Style B Wear Plate Installation........................................................................................... 0258-13 Style B Wear Plate Installation........................................................................................... 0258-14 Style B Wear Plate Installation........................................................................................... 0258-15 Style B Wear Plate Installation........................................................................................... 0258-16 Style C (RT 240V1 and RT 240V1R) Wear Plate Replacement........................................ 0258-17 Style D (RT 240V2 and RT 240V3 ONLY) Wear Plate Replacement................................ 0258-18

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TABLE OF CONTENTS - Continued


Page No. WP Sequence No. TOPHANDLER REPLACEMENT................................................................................................................ WP 0259 Figure 1. Figure 2. Figure 3. Figure 4. Figure 5. Figure 6. Figure 7. Figure 8. Figure 9. Figure 10. Figure 11. Figure 12. Figure 13. Figure 14. Figure 15. Figure 16. Figure 17. Figure 18. Figure 19. Figure 20. Figure 21. Figure 22. Tophandler Removal............................................................................................................ 0259-2 Tophandler Removal............................................................................................................ 0259-3 Tophandler Removal............................................................................................................ 0259-3 Tophandler Removal............................................................................................................ 0259-4 Tophandler Removal............................................................................................................ 0259-5 Tophandler Removal............................................................................................................ 0259-5 Tophandler Removal............................................................................................................ 0259-6 Tophandler Removal............................................................................................................ 0259-6 Tophandler Removal............................................................................................................ 0259-7 Tophandler Removal............................................................................................................ 0259-7 Tophandler Removal............................................................................................................ 0259-8 Tophandler Removal............................................................................................................ 0259-9 Tophandler Removal............................................................................................................ 0259-9 Tophandler Removal.......................................................................................................... 0259-10 Tophandler Installation....................................................................................................... 0259-10 Tophandler Installation....................................................................................................... 0259-11 Tophandler Installation....................................................................................................... 0259-11 Tophandler Installation....................................................................................................... 0259-12 Tophandler Installation....................................................................................................... 0259-13 Tophandler Installation....................................................................................................... 0259-13 Tophandler Installation....................................................................................................... 0259-14 Tophandler Installation....................................................................................................... 0259-14

SPREADER CHAIN MAINTENANCE.......................................................................................................... WP 0260 Figure 1. Figure 2. Figure 3. Access Panels Removal....................................................................................................... 0260-1 Protective Plate Removal..................................................................................................... 0260-2 Sliding Beam Removal from Main Beam.............................................................................. 0260-2

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TABLE OF CONTENTS - Continued


Page No. WP Sequence No. Figure 4. Figure 5. Figure 6. Figure 7. Figure 8. Figure 9. Figure 10. Figure 11. Figure 12. Figure 13. Figure 14. Figure 15. Figure 16. Figure 17. Sliding Beam Reference Mark.............................................................................................. 0260-3 Chain Tensioner Removal.................................................................................................... 0260-3 Locking Plate Removal......................................................................................................... 0260-4 Chain Anchor Access........................................................................................................... 0260-5 Beam and Tensioner Locknut Removal............................................................................... 0260-5 Hydraulic/Electrical Hose Power Track Support Removal................................................... 0260-6 Chain Anchor Removal........................................................................................................ 0260-7 Position Slide Beam............................................................................................................. 0260-8 Assemble Chain Anchor....................................................................................................... 0260-9 Idler Shaft Locking Plate Installation.................................................................................... 0260-9 Chain Adjustment............................................................................................................... 0260-10 Chain Tension Adjustment................................................................................................. 0260-11 Chain Adjuster Vertical Adjustment (RT 240V1 and RT 240V1R only).............................. 0260-12 Chain Adjuster Vertical Adjustment (RT 240V1 and RT 240V1R only).............................. 0260-13

SPREADER 20 AND 40 FOOT ADJUSTMENT.......................................................................................... WP 0261 Figure 1. Figure 2. Figure 3. Figure 4. Figure 5. Figure 6. Figure 7. Figure 8. Measurement and Adjustment - 20 Ft.................................................................................. 0261-1 Measurement and Adjustment - 20 Ft.................................................................................. 0261-2 Measurement and Adjustment - 20 Ft.................................................................................. 0261-3 Measurement and Adjustment - 20 Ft.................................................................................. 0261-3 Measurement and Adjustment - 40 Ft.................................................................................. 0261-4 Measurement and Adjustment - 40 Ft.................................................................................. 0261-4 Measurement and Adjustment - 40 Ft.................................................................................. 0261-5 Measurement and Adjustment - 40 Ft.................................................................................. 0261-5

SPREADER MAINTENANCE...................................................................................................................... WP 0262 Figure 1. Figure 2. Hydraulic Motor Replacement.............................................................................................. 0262-2 Gear Installation................................................................................................................... 0262-3

TOPHANDLER WEAR PLATES (SLIDE PLATE) REPLACEMENT............................................................ WP 0263

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TABLE OF CONTENTS - Continued


Page No. WP Sequence No. Figure 1. Figure 2. Figure 3. Figure 4. Figure 5. Figure 6. Figure 7. Figure 8. Figure 9. Figure 10. Figure 11. Figure 12. Figure 13. Figure 14. Tophandler Wear Plate Locations........................................................................................ 0263-3 Tophandler Wear Plate Locations........................................................................................ 0263-4 Style A Wear Plate Removal................................................................................................ 0263-5 Style A Wear Plate Replacement......................................................................................... 0263-6 Style B Wear Plate Removal................................................................................................ 0263-7 Style B Wear Plate Removal................................................................................................ 0263-8 Style B Wear Plate Removal................................................................................................ 0263-9 Style B Wear Plate Removal.............................................................................................. 0263-10 Style B Wear Plate Installation........................................................................................... 0263-11 Style B Wear Plate Installation........................................................................................... 0263-12 Style B Wear Plate Installation........................................................................................... 0263-13 Style C Wear Plate Replacement....................................................................................... 0263-15 Style D Wear Plate Replacement....................................................................................... 0263-17 Style E Wear Plate Replacement....................................................................................... 0263-18

TOPHANDLER HYDRAULIC SPREADER MOTOR MAINTENANCE........................................................ WP 0264 Figure 1. Figure 2. Figure 3. Figure 4. Figure 5. Figure 6. Figure 7. Figure 8. Tophandler Access Panels Removal................................................................................... 0264-2 Tophandler Access Panels Removal................................................................................... 0264-3 Chain Adjuster Measurement and Removal......................................................................... 0264-3 Tophandler Hydraulic Spreader Removal............................................................................ 0264-4 Tophandler Hydraulic Spreader Installation......................................................................... 0264-5 Chain Adjuster Installation and Measurement...................................................................... 0264-6 Access Panels Installation.................................................................................................... 0264-6 Access Panels Installation.................................................................................................... 0264-7

PREPARATION FOR ARCTIC OPERATION.............................................................................................. WP 0265 Figure 1. Twistlock Cylinder Bypass Valve.......................................................................................... 0265-2

PREPARATION FOR STORAGE OR SHIPMENT...................................................................................... WP 0266 ELECTRICAL GENERAL MAINTENANCE INSTRUCTIONS..................................................................... WP 0267

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TABLE OF CONTENTS - Continued


Page No. WP Sequence No. Figure 1. Figure 2. Figure 3. Figure 4. Figure 5. Figure 6. Figure 7. Figure 8. Figure 9. Figure 10. Figure 11. Figure 12. Figure 13. Figure 14. Figure 15. Figure 16. Figure 17. Figure 18. Figure 19. Figure 20. Multi-Pin Connector Identifier............................................................................................... 0267-2 Multi-Pin Connector Identifier............................................................................................... 0267-3 Multi-Pin Connector Identifier............................................................................................... 0267-4 Multi-Pin Connector Identifier............................................................................................... 0267-5 Connector Repair................................................................................................................. 0267-6 Connector Repair................................................................................................................. 0267-6 Sealed Connector Repair..................................................................................................... 0267-7 Receptacle Connector Repair.............................................................................................. 0267-8 Waterproof Connector Repair.............................................................................................. 0267-9 Military Connector Repair................................................................................................... 0267-10 Ring Terminal Repair......................................................................................................... 0267-11 Wire Splicing...................................................................................................................... 0267-12 Electrical Ground Points..................................................................................................... 0267-13 Multimeter Usage............................................................................................................... 0267-14 Multimeter Usage............................................................................................................... 0267-15 Multimeter Usage............................................................................................................... 0267-16 Multimeter Usage............................................................................................................... 0267-17 Multimeter Usage............................................................................................................... 0267-18 Relay Inspection and Test.................................................................................................. 0267-19 Solenoid Inspection and Test............................................................................................. 0267-20

GENERAL MAINTENANCE INSTRUCTIONS............................................................................................. WP 0268 Table 1. Table 2. Table 3. Table 4. Table 5. Boss Type O-rings................................................................................................................ 0268-7 Flat-Face Type O-rings........................................................................................................ 0268-8 O-ring/Retainer Type Fitting Seals....................................................................................... 0268-8 Split Flange Type O-rings..................................................................................................... 0268-8 Hydraulic Hose Torque Chart............................................................................................... 0268-9

ILLUSTRATED LIST OF MANUFACTURED ITEMS................................................................................... WP 0269

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TABLE OF CONTENTS - Continued


Page No. WP Sequence No. Figure 1. Stud, Guide.......................................................................................................................... 0269-1

TORQUE LIMITS......................................................................................................................................... WP 0270 Figure 1. Table 1. Torque Patterns.................................................................................................................... 0270-2 Torque Limits........................................................................................................................ 0270-2

LOAD TESTING PROCEDURE................................................................................................................... WP 0271 Figure 1. Table 1. Figure 2. Figure 3. Figure 4. Table 2. Boom Cylinder Drift Test...................................................................................................... 0271-2 Reference Readings 1.......................................................................................................... 0271-3 Boom Cylinder Drift Test...................................................................................................... 0271-3 Extension Cylinder Drift Test................................................................................................ 0271-4 Extension Cylinder Drift Test................................................................................................ 0271-5 Reference Readings 2.......................................................................................................... 0271-5

SCHEMATICS............................................................................................................................................. WP 0272 Figure 1. Figure 1. Figure 1. Figure 2. Figure 2. Figure 2. Figure 2. Figure 2. Figure 3. Figure 3. Figure 4. Figure 4. Figure 4. Figure 4. Figure 5. ECS Display/CAN-BUS (A34647.0200). (Sheet 1 of 3) ...................................................... 0272-7 ECS Display/CAN-BUS (A34647.0200). (Sheet 2 of 3) ...................................................... 0272-8 ECS Display/CAN-BUS (A34647.0200). (Sheet 3 of 3) ...................................................... 0272-9 ECS Electrical Servo (A34648.0200). (Sheet 1 of 5) ........................................................ 0272-10 ECS Electrical Servo (A34648.0200). (Sheet 2 of 5) ........................................................ 0272-11 ECS Electrical Servo (A34648.0200). (Sheet 3 of 5) ........................................................ 0272-12 ECS Electrical Servo (A34648.0200). (Sheet 4 of 5) ........................................................ 0272-13 ECS Electrical Servo (A34648.0200). (Sheet 5 of 5) ........................................................ 0272-14 ECS Engine (A34648.0200). (Sheet 1 of 2) ...................................................................... 0272-15 ECS Engine (A34648.0200). (Sheet 2 of 2) ...................................................................... 0272-16 ECS Transmission (A34650.0200). (Sheet 1 of 4) ............................................................ 0272-17 ECS Transmission (A34650.0200). (Sheet 2 of 4) ............................................................ 0272-18 ECS Transmission (A34650.0200). (Sheet 3 of 4) ............................................................ 0272-19 ECS Transmission (A34650.0200). (Sheet 4 of 4) ............................................................ 0272-20 ECS Steering (A34651.0200). (Sheet 1 of 7) .................................................................... 0272-21

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TABLE OF CONTENTS - Continued


Page No. WP Sequence No. Figure 5. Figure 5. Figure 5. Figure 5. Figure 5. Figure 5. Figure 6. Figure 6. Figure 6. Figure 6. Figure 6. Figure 6. Figure 7. Figure 7. Figure 8. Figure 8. Figure 8. Figure 8. Figure 9. Figure 10. Figure 10. Figure 11. Figure 12. Figure 13. Figure 14. Figure 14. Figure 14. ECS Steering (A34651.0200). (Sheet 2 of 7) .................................................................... 0272-22 ECS Steering (A34651.0200). (Sheet 3 of 7) .................................................................... 0272-23 ECS Steering (A34651.0200). (Sheet 4 of 7) .................................................................... 0272-24 ECS Steering (A34651.0200). (Sheet 5 of 7) .................................................................... 0272-25 ECS Steering (A34651.0200). (Sheet 6 of 7) .................................................................... 0272-26 ECS Steering (A34651.0200). (Sheet 7 of 7) .................................................................... 0272-27 ECS Attachment to Tophandler (A34652.0200). (Sheet 1 of 6) ........................................ 0272-28 ECS Attachment to Tophandler (A34652.0200). (Sheet 2 of 6) ........................................ 0272-29 ECS Attachment to Tophandler (A34652.0200). (Sheet 3 of 6) ........................................ 0272-30 ECS Attachment to Tophandler (A34652.0200). (Sheet 4 of 6) ........................................ 0272-31 ECS Attachment to Tophandler (A34652.0200). (Sheet 5 of 6) ........................................ 0272-32 ECS Attachment to Tophandler (A34652.0200). (Sheet 6 of 6) ........................................ 0272-33 Hydraulics (A34654.0200). (Sheet 1 of 2) ......................................................................... 0272-34 Hydraulics (A34654.0200). (Sheet 2 of 2) ......................................................................... 0272-35 Current Supply (A34738.0200). (Sheet 1 of 4) .................................................................. 0272-36 Current Supply (A34738.0200). (Sheet 2 of 4) .................................................................. 0272-37 Current Supply (A34738.0200). (Sheet 3 of 4) .................................................................. 0272-38 Current Supply (A34738.0200). (Sheet 4 of 4) .................................................................. 0272-39 Shifting (A34739.0200). (Sheet 1 of 1) .............................................................................. 0272-40 Sender (A34740.0200). (Sheet 1 of 2) .............................................................................. 0272-41 Sender (A34740.0200). (Sheet 2 of 2) .............................................................................. 0272-42 Wipers (A34741.0200). (Sheet 1 of 1) ............................................................................... 0272-43 AC and Fan (A34742.0200). (Sheet 1 of 1) ....................................................................... 0272-44 Cab (A34743.0200). (Sheet 1 of 1) ................................................................................... 0272-45 Lights (A34744.0200). (Sheet 1 of 5) ................................................................................ 0272-46 Lights (A34744.0200). (Sheet 2 of 5) ................................................................................ 0272-47 Lights (A34744.0200). (Sheet 3 of 5) ................................................................................ 0272-48

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TABLE OF CONTENTS - Continued


Page No. WP Sequence No. Figure 14. Figure 14. Figure 15. Figure 16. Figure 17. Figure 18. Figure 18. Figure 19. Figure 20. Figure 21. Figure 22. Figure 23. Figure 24. Figure 25. Lights (A34744.0200). (Sheet 4 of 5) ................................................................................ 0272-49 Lights (A34744.0200). (Sheet 5 of 5) ................................................................................ 0272-50 Work Lights (A34745.0200). (Sheet 1 of 1) ....................................................................... 0272-51 Auxiliary Pump (A34746.0200). (Sheet 1 of 1) .................................................................. 0272-52 Auto Lubrication (A48665.0100). (Sheet 1 of 1) ................................................................ 0272-53 Information (A34749.0200). (Sheet 1 of 2) ........................................................................ 0272-54 Information (A34749.0200). (Sheet 2 of 2) ........................................................................ 0272-55 Steering System................................................................................................................. 0272-56 Brake System..................................................................................................................... 0272-57 Main System....................................................................................................................... 0272-58 Tophandler System............................................................................................................ 0272-59 Autolube System Tubing Layout........................................................................................ 0272-60 Electrical Symbols.............................................................................................................. 0272-61 Hydraulic Symbols.............................................................................................................. 0272-62

Chapter 6 - SUPPORTING INFORMATION REFERENCES............................................................................................................................................ WP 0273 MAINTENANCE ALLOCATION CHART (MAC) INTRODUCTION.............................................................. WP 0274 MAINTENANCE ALLOCATION CHART FOR THE RTCH.......................................................................... WP 0275 Table 1. Table 2. Table 3. Maintenance Allocation Chart (MAC)................................................................................... 0275-1 Tools and Test Equipment................................................................................................. 0275-24 Remarks............................................................................................................................. 0275-27

EXPENDABLE AND DURABLE ITEMS LIST.............................................................................................. WP 0276 Table 1. Expendable and Durable List for the RTCH......................................................................... 0276-1

TOOL IDENTIFICATION LIST..................................................................................................................... WP 0277 Table 1. Tool Identification List........................................................................................................... 0277-1

MANDATORY REPLACEMENT PARTS LIST............................................................................................ WP 0278 Table 1. Index Mandatory Replacement Parts List...................................................................................... 0278-1

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HOW TO USE THIS MANUAL

INTRODUCTION 1. This manual is designed to help you perform Field level Maintenance and Troubleshooting on all variants of the RT 240 Rough Terrain Container Handler (RTCH). For model-specific information, see matrix below: RT 240V1 (NSN 3930-01-473-3998) S/N range T34112.0003 to T35112.0373 RT 240V1R (NSN 3930-01-473-3998) S/N range T34112.0003(R) to T35112.0373(R) RT 240V2 (NSN 3930-01-522-7364, and 3930-01-473-3889) S/N range T5112.0401 to T35112.0742 RT 240V3 (NSN 3930-01-522-7364, and 3930-01-473-3889) S/N range S112.00801 to current

NOTE
RT 240V2 and V3 models are identical, the only difference between the two models, are the RT 240V3 machines were built in the United States. Any models that have been reset will have one or more "R" stamped at the end of their S/N or the RESET date will be stamped in the Data plate. For model specific information, the configuration name (RT 240V1, RT 240V1R, RT 240V2/3) will be specified in the task title in parentheses (for maintenance tasks) and in the table/errors code title in parentheses (for Troubleshooting procedures). If there is no designation, the task/troubleshooting procedure applies to all models.

2. The Repair Parts and Special Tools List (RPSTL), TM 10-3930-675-24P, is to be used in conjunction with this manual to locate and obtain the repair parts and special tools needed to maintain this equipment. 3. This manual is written in Work Package format: a. Chapters divide the manual into major categories of information (e.g., General Information, Theory of Operation, Troubleshooting Procedures, Maintenance Instructions, and Supporting Information). b. Each Chapter is divided into Work Packages, which are identified by a 4-digit number (e.g., 0001, 0002) located on the upper right-hand corner of each page. The Work Package page number (e.g., 0001-1, 0001-2) is located centered at the bottom of each page. c. If a Change Package is issued to this manual, added Work Packages use the 5th and 6th digits of their number to indicate new material. For instance, Work Packages inserted between WP 0001 and WP 0002 are numbered WP 0001 01, WP 0001 02, etc. 4. This manual is published in two volumes: Volume I covers Chapters 1 and 2, Work Packages 0001 through WP 0048 and includes all troubleshooting, Chapter 6: Supporting Information is included in Volumes I and II. Volume II includes Chapters 3 through 6, WP 0049 through WP 0292. 5. Scan through this manual to become familiar with its organization and contents before attempting to maintain the equipment.

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HOW TO USE THIS MANUAL - Continued

CONTENTS OF THIS MANUAL 1. A Warning Summary is located at the beginning of each volume of the manual. Become familiar with these warnings before operating or performing troubleshooting or maintenance on the vehicle. 2. A Table of Contents in Volume I lists the contents of Volumes I and II. The Table of Contents in Volume II lists the contents of Volume II only. a. The Table of Contents also provides Reporting Errors and Recommending Improvements information and DA Form 2028 addresses, for the submittal of corrections to the manual. b. If you cannot find what you are looking for in the Table of Contents, refer to the alphabetical Index at the back of the manual. The alphabetical Index for each volume lists only those Work Packages found in that volume. 3. Chapter 1, General Information, Equipment Description, and Theory of Operation, provides general information on the manual and the equipment. 4. Chapter 2, Troubleshooting Procedures, contains all applicable troubleshooting and a complete listing of Error Codes resident on the RTCH. 5. a. Before attempting to perform troubleshooting, carefully read the information in WP 0004, Troubleshooting Introduction. It explains how to perform both non-error code and error code-driven troubleshooting. Included at the end of this Work Package are locator diagrams of all electrical and hydraulic components that may be hard to locate. b. The error code reference index in WP 0004 provides a numerical list of error codes. c. The Troubleshooting Symptom Index in WP 0005 is divided into three sections. The first is an Alphabetical Error Code Symptom Index", the second is a Numerical Error Code Symptom Index", and the third is a Non-Error Code Symptom Index". d. The corrective action for certain malfunctions is to notify SRA". Refer to Table 3 in the Maintenance Allocation Chart (MAC) (Volume 2, WP 0275) for further information about the Specialized Repair Activity for the RTCH. 6. Chapter 3 covers all Maintenance Instructions. In each chapter, work packages are organized in the same Functional Group Code (FGC) sequence as the MAC found in Chapter 6 of both volumes. 7. Chapter 6 includes Supporting Information: References, MAC Introduction, MAC, Expendable and Durable Items List, Load Testing Procedure, and Foldouts of Hydraulic Systems. 8. An alphabetical index completes the manual. FEATURES OF THIS MANUAL 1. WARNINGs, CAUTIONs, NOTEs, subject headings, and other important information are highlighted in BOLD print as a visual aid. 2. a. WARNING indicates a hazard which may result in death or serious injury to personnel. b. CAUTION is a reminder of safety practices or directs attention to usage practices that may result in damage to equipment. c. NOTE is a statement containing information that will make the procedures easier to perform. 3. Statements and words of particular interest may be printed in CAPITAL LETTERS to create emphasis. 4. Within a procedural step, reference may be made to another Work Package in this manual or to another manual. These references indicate where you should look for more complete information. 5. a. If you are told: Replace engine ECU (WP 0079)", go to the Table of Contents in Volume II of this manual for instructions on replacing the engine ECU. Be sure to read the Initial Setup" on page 1 of the Work Package, to determine contents of Work Package as well as information regarding tools and equipment, spare parts, and personnel required, etc. b. If you are told: Check coolant level (TM 10-3930-675-10)", go to TM 10-3930-675-10. Use the Table of Contents or alphabetical Index in TM 10-3930-675-10 to find the procedure.

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HOW TO USE THIS MANUAL - Continued


FEATURES OF THIS MANUAL - Continued 6. Illustrations are placed after, and as close to, the procedural steps to which they apply. Callouts placed on the art may be text or numbers, whichever method is easier for the soldier. 7. Numbers located at lower right corner of art (e.g., 350-001; 434-0002) are art control numbers and are used for tracking purposes. Disregard these numbers. 8. Dashed leader lines used in illustrations indicate that called out items are not visible in the view depicted (i.e., they are located within or behind the structure). 9. Technical instructions include metric units as well as standard units. For your reference, a Metric Conversion Chart is located on the inside back cover of the manual.

NOTE
If at any time you are unsure how to use this manual or you cannot locate the information you need, notify your Supervisor.

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CHAPTER 1 GENERAL INFORMATION, EQUIPMENT DESCRIPTION, AND THEORY OF OPERATION

TM 10-3930-675-23-1

0001

FIELD MAINTENANCE GENERAL INFORMATION

SCOPE 1. Type of Manual. This manual is designed for use in performing field maintenance and troubleshooting on the Rough Terrain Container Handler (RTCH) (all models).

NOTE
RT 240V2 and RT 240V3 models are identical; the only difference between the two models is that the RT 240V3 machines were built in the United States. Any models that have been reset will have one or more "R" stamped at the end of their S/N or the RESET date will be stamped in the Data plate. RT 240V1 (NSN 3930-01-473-3998) S/N range T34112.0003 to T35112.0373 RT 240V1R (NSN 3930-01-473-3998) S/N range T34112.0003(R) to T35112.0373(R) RT 240V2 (NSN 3930-01-522-7364, and 3930-01-473-3998) S/N range T5112.0401 to T35112.0742 RT 240V3 (NSN 3930-01-522-7364, and 3930-01-473-3998) S/N range S112.00801 to current 2. Purpose of Equipment. The RTCH (all models) is designed to lift and stack 20 and 40 ft International Standard Organization (ISO) containers, loaded to a gross weight of 53,000 lb (24,062 kg). MAINTENANCE FORMS, RECORDS, AND REPORTS Department of the Army forms and procedures used for the equipment will be those prescribed by DA PAM 750-8, The Army Maintenance Management System (TAMMS) Users Manual. REPORTING EQUIPMENT IMPROVEMENT RECOMMENDATIONS (EIR) If your RTCH set needs improvement, let us know. Send us an EIR. You, the user, are the only one who can tell us what you do not like about the equipment. Let us know why you do not like the design or performance. If you have Internet access, the easiest and fastest way to report problems or suggestions is to go to http://www.nslcptsmh.csd.disa.mil/webpqdr/webpqdr.htm. The Internet form lets you submit a Product Quality Deficiency Report (PQDR). You may also submit your information using an SF Form 368, Product Quality Deficiency Report. You can send your SF 368 via e-mail, regular mail, or facsimile directly to the U.S. Army TACOM Life Cycle Management Command. The postal mail address is U.S. Army TACOM Life Cycle Management Command, ATTN: AMSRD-TAR-E/PDQR, MS 268, 6501 E. 11 mile Road, Warren, MI 48397-5000. The e-mail address is dami_tacomdrs@conus.army.mil. The fax number is DSN 786-5666 or Commercial 586-282-5666.

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0001

CORROSION PREVENTION AND CONTROL (CPC) Corrosion Prevention and Control (CPC) of Army materiel is a continuing concern. It is important that any corrosion problems with this item be reported so that the problem can be corrected and improvements can be made to prevent the problem in future items. Corrosion specifically occurs with metals. It is an electrochemical process that causes the degradation of metals. It is commonly caused by exposure to moisture, acids, bases, or salts. An example is the rusting of iron. Corrosion damage in metals can be seen, depending on the metal, as tarnishing, pitting, fogging, surface residue, and/or cracking. Plastics, composites, and rubbers can also degrade. Degradation is caused by thermal (heat), oxidation (oxygen), solvation (solvents), or photolytic (light, typically UV) processes. The most common exposures are excessive heat or light. Damage from these processes will appear as cracking, softening, swelling, and/or breaking. SF 368, Product Quality Deficiency Report should be submitted to the address specified in DA PAM 750-8, The Army Maintenance Management System (TAMMS) Users Manual. OZONE DEPLETING SUBSTANCES Listing to be provided by requiring activity. DESTRUCTION OF ARMY MATERIEL TO PREVENT ENEMY USE For destruction of Army materiel to prevent enemy use, refer to TM 750-244-6. PREPARATION FOR STORAGE OR SHIPMENT For preparation for storage or shipment procedures, refer to TM 10-3930-675-10. WARRANTY INFORMATION The vehicles are warranted by Kalmar RT in accordance with TB 10-3930-675-14. Warranty starts on the date found in block 23, DA Form 2408-9 in the logbook. Report all defects in material or workmanship to your Supervisor, who will take appropriate action. LIST OF ABBREVIATIONS/ACRONYMS

NOTE
Refer to ASME Y14.38 for standard abbreviations. Table 1. List of Abbreviations/Acronyms. ABBREVIATIONS/ACRONYMS DEFINITION AAL BII C CAN-BUS CBRN CID cm Additional Authorization List Basic Issue Items Centigrade or Celsius Controller Area Network-BUS Chemical, Biological, Radiological and Nuclear Cubic Inch Displacement Centimeter 0001-2

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LIST OF ABBREVIATIONS/ACRONYMS - Continued Table 1. List of Abbreviations/Acronyms - Continued.

ABBREVIATIONS/ACRONYMS DEFINITION COEI CPC ECM ECS ECU EEPROM F FGC ft GCWR GVWR IETM hp in ISO kg km kPa kph kW L lb lb-ft lph Components of End Item Corrosion Prevention and Control Electronic Control Module Electronic Control System Electronic Control Units Electrically-Erasable Programmable Read-Only Memory Fahrenheit Functional Group Code Feet Gross Combination Weight Rating Gross Vehicle Weight Rating Interactive Electronic Technical Manual Horsepower Inch International Standards Organization Kilogram Kilometer Kilopascal Kilometers per Hour Kilowatt Liter Pound Pound Foot Liters per Hour

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LIST OF ABBREVIATIONS/ACRONYMS - Continued Table 1. List of Abbreviations/Acronyms - Continued.

ABBREVIATIONS/ACRONYMS DEFINITION m MAC mm mph NATO Nm OEM PMCS PTO RTCH SOP SPORT SRA TAMMS ULLS-G V yd QUALITY OF MATERIAL Material used for replacement, repair, or modification must meet the requirements of this manual. If quality of material requirements are not stated in this manual, the material must meet the requirements for the drawings, standards, specifications, or approved engineering change proposals applicable to the subject equipment. END OF WORK PACKAGE Meter Maintenance Allocation Chart Millimeter Mile Per Hour North Atlantic Treaty Organization Newton Meter Original Equipment Manufacturer Preventive Maintenance Checks and Services Power Take-Off Rough Terrain Container Handler Standard Operating Procedure Soldiers Portable On-System Repair Tool Specialized Repair Activity The Army Maintenance Management System Unit Level Logistics System - Ground Volt(s) Yard

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FIELD MAINTENANCE EQUIPMENT DESCRIPTION AND DATA

EQUIPMENT CHARACTERISTICS, CAPABILITIES, AND FEATURES 1. Characteristics. a. The Rough Terrain Container Handler (RTCH) is designed to lift, move, stack, or unstack 20 and 40 ft (6.10 to 12.19 m) by 8 ft (2.44 m) wide ISO containers. b. The RTCH has a lift capacity of 53,000 lb (24,040 kg) and operates on hard and/or unimproved surfaces, to include beach operations. c. The RTCH can be utilized as a forklift with an operator-installed forklift kit. 2. Capabilities and Features. a. Capabilities. (1) Container handling capabilities: Stack or unstack 8 ft (2.44 m) high ISO containers stacked three (3) high with a gross weight of 53,000 lb (24,040 kg) in the first row. Stack or unstack 8 ft (2.44 m) high ISO containers stacked three (3) high with a gross weight of 27,500 lb (12,474 kg) in the second row. Stack or unstack 4.3 ft (1.31 m) high ISO containers stacked seven (7) high. Container tophandler adjusts to 20 or 40 ft (6.10 to 12.19 m) ISO container lengths. Container tophandler oscillates 7 degrees left and right. Container tophandler rotates 195 degrees clockwise and 105 degrees (145 degrees for RT 240V2 and RT 240V3) counterclockwise. Container tophandler tilts 8 degrees forward and 12 degrees to the rear. Container tophandler side shifts 15 in. ( 381 mm) from the center. (2) Forklift kit is operator-installed and attaches to the tophandler. The forktines are adjustable from 24 in. (61cm) center-to-center to 81.5 in. (207 cm) center-to-center. Lift capacity is 44,000 lb (19,958 kg). (3) Maximum speed of RTCH is 23 mph (37 kph) on level ground with NO LOAD; maximum speed on level ground LOADED is 15 mph (24 kph). (4) Maximum fording depth is 60 in. (1.52 m). (5) Operation in temperatures from -25F (-32C) to +125F (+52C), and to -40F (-40C) with arctic kit installed. b. Features. (1) Electronically-controlled 400 hp, six-cylinder turbocharged engine. (2) Electronic semi-automatic shift controlled transmission with 4 ranges forward and 3 reverse. Operator selects range and ECM controls shift points. (3) The drive axles provide traction for 2-wheel or 4-wheel drive. (4) Limited slip differentials and multi-disc wet brakes are an integral part of the axle assemblies. Multi-disc wet brakes are hydraulically cooled to prevent overheating. Accumulators store energy for the emergency braking system. (5) The steering system is capable of 2-wheel, 4-wheel, crab, and emergency modes of operation. (6) The parking brake is hydraulically released and spring-applied by disc brake assemblies mounted on the front and rear differentials. (7) The operator's cab has a fully adjustable operator's seat, fresh air (filtered) ventilation system, and heater/defroster/air conditioning systems. (8) Operator's controls include: adjustable steering wheel; accelerator and brake pedals; transmission range selector; steering mode selection rocker switches; and a single joystick control for all boom, tophandler, and forklift operations.

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0002

c.

Transport Modes.

NOTE
Refer to TM 10-3930-675-10 for detailed instructions to prepare the RTCH for transport. Self Deployment Highway Transport Rail Transport Marine Transport Air Transport

LOCATION AND DESCRIPTION OF MAJOR COMPONENTS


2 3 4 5 1

G0007JCH

Figure 1. Table 1. KEY 1 COMPONENT Tophandler

Major Components.

Description of Major Components

DESCRIPTION Electro-hydraulically operated 20 to 40 ft (6.10 to 12.19 m) tophandler. Capable of sideshifting, rotation, forward/rear tilting, left/right tilting, and load position leveling and locking. Also interfaces with forklift attachment. Electro-hydraulically operated heavy duty steel boom designed for moving, lifting, and stacking 20 to 40 ft (6.10 to 12.19 m) ISO containers. Electro-hydraulically operated cylinders raise, lower, and support the boom assembly. Contains all driving and container handling controls as well as heating, air conditioning, and filtered ventilation system controls. During air transport operations, the cab is moved to the left side of the chassis, then lowered and secured in place.

Boom Assembly

Boom Lift Cylinders

Operator's Cab

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LOCATION AND DESCRIPTION OF MAJOR COMPONENTS - Continued Table 1. KEY 5 COMPONENT Boom Support Description of Major Components - Continued DESCRIPTION Rear support and pivot point for the boom to include an unlocking device that allows the boom assembly to be lowered into the transport position. A heavy-duty steel construction with tie-downs, towing lugs, and pintle hook. Location of selected hydraulic remote controls. Also access to hydraulic system test and sampling ports.

Frame

Remote Hydraulic Control Compartment

12

11

10

8
G0005JCH

Figure 2. Table 2. KEY 8 COMPONENT Dolly Wheels Storage Compartment Master Battery Switch

Major Components.

Description of Major Components

DESCRIPTION Storage location for the attachable tophandler air transport dolly wheels.

ON/OFF control of electrical power from batteries to vehicle electrical system. Provides an electrical connection for slave starting. A receptacle is located on each side of the RTCH. Stores four 12V batteries and required cabling. Batteries are accessible from the side and/or the top. Electro-hydraulically operated and monitored ISO twistlocks, located at each corner of the tophandler. Also utilized to attach forklift attachment to tophandler.

10

Slave Receptacle

11

Battery Compartment

12

Twistlocks

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13 18 20 19 17 16 15 14 10
G0006JCH

Figure 3. Table 3. KEY 13 COMPONENT Front Service and Blackout Lights Coolant Expansion Tank

Major Components.

Description of Major Components

DESCRIPTION Headlight, blackout drive light, and composite turn signal with blackout markers. Contains cooling system overflow. Provides means to visually check coolant level and add coolant to system. Houses the six-cylinder turbocharged diesel engine that supplies power for the automotive, electrical, and hydraulic systems. Stores and vents system hydraulic oil. Visual indicator of hydraulic oil level. If oil is NOT visible in sight gauge with boom completely lowered and tophandler retracted, DO NOT start engine. Stores fuel supply for vehicle. Composite tail, stop, and blackout markers; turn signals; and backup lights. Allow weight of machine to be distributed over more wheel area during aircraft loading and transport.

14

15

Engine Compartment

16 17

Hydraulic Reservoir Hydraulic Reservoir Sight Gauge

18 19

Fuel Tank Rear Service and Blackout Lights Bogie Wheels

20

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EQUIPMENT DATA Engine: Manufacturer Model Horsepower @ 2,150 RPM Torque @ 1,200 RPM Cylinders Displacement Weight Fuel System Cooling System, Thermostat Range NOTE RT 240V1R machines will either use 6WG-260 or 4WG-310 depending on what they received during RESET. Transmission: Manufacturer Model RT 240V1 Model RT 240V2 and RT 240V3 Type Range Selection ZF-Hydromedia 6WG-260 4WG-310 4 forward and 3 reverse speeds Automatic, electronically controlled Cummins QSM 11 400 hp (298 kW) 1,450 lb-ft (1,966 Nm) 6 661 CID (10.8 L) 2,070 lb (940 kg) Fully electronic 180 to 200F (82 to 93C)

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EQUIPMENT DATA - Continued Axles: Manufacturer Model: Front (RT 240V1, RT 240V1R, and RT 240V2) Rear (RT 240V1, RT 240V1R, and RT 240V2) Front (RT 240V3) Rear (RT 240V3) Weight: Front Rear Tires: Front and Rear: Manufacturer Size Inflation Weight RT 240V1 Weight RT 240V1R, RT 240V2, and RT 240V3 Bogie Wheels (Transport Operations): Manufacturer Size Inflation Dolly Wheels (Tophandler Transport): Manufacturer Size Inflation Michelin 225/75 R 10 XZR 85 psi (586 kPa) Michelin 355/65 R 15 XZM 85 psi (586 kPa) Bridgestone 29.5 35 Series 85 psi (586 kPa) 2,315 lb (1,050 kg) 2,750 lb (1,247 kg) 8,379 lb (3,800 kg) 5,733 lb (2,600 kg) LT102PL341/528NLB4650 Kessler

LT102PL341/528NLB4460

LT102PL341/528NLB5550 LT102PL341/528NLB4460-1

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EQUIPMENT DATA - Continued Dimensions: Length: Tophandler Lateral Tophandler Longitudinal Height: Operational w/Boom Level Highway Transport Mode Width, Tophandler Longitudinal Weights: GVWR w/All Fluids RT 240V1 GVWR w/Forklift Kit RT 240V1 GVWR Operational w/All Fluids (RT 240V1R, RT 240V2, and RT 240V3) GVWR Operational w/Forklift Kit and/all Fluids (RT 240V1R, RT 240V2, and RT 240V3) Capacities: Fuel Tank Cooling System Cooling, Engine Only Hydraulic Oil Reservoir Engine Crankcase w/Filter Transmission w/Filter Electrical System: Type Battery Manufacturer Model Hawker, Armasafe Plus Armasafe Plus Battery 24V, negative ground 103 gal. (390 L) 23.7 gal. (90.1 L) 3.4 gal. (12.9 L) 180 gal. (680 L) 38.6 qt (36.5 L) 36 qt (34 L) 118,000 lb (53,524 kg) 128,400 lb (58,241 kg) 118,500 lb (53,751 kg) 13.1 ft (4.0 m) 9.8 ft (3.0 m) 12 ft (3.66 m) 37.7 ft (11.0 m) 49.2 ft (15.0 m)

130,050 lb (58,990 kg)

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EQUIPMENT DATA - Continued Voltage Plates per cell Rating Cold Cranking Amps (CCA SAE) Mass Number of batteries per vehicle Temperature at time of full charge Miscellaneous: Maximum Lifting Capacity: First Stacking Row Second Stacking Row Maximum Lift Height Maximum Lifting Capacity, w/Forklift Kit: First Stacking Row Second Stacking Row Maximum Lift Height, w/Forklift Kit 44,000 lb (19,958 kg) 24,600 lb (11,158 kg) 21.8 ft (6.65 m) 53,000 lb (24,040 kg) 27,500 lb (12,474 kg) 33 ft (10.06 m) 12V 6 Cell lead acid 120 A/h, electrical capacity 1,225 Amps per battery 86 lb (39 kg) 4 68 F (20 C)

Forklift Kit, Fork Tines Center-to-Center Range 24 to 81.5 inch (61 to 207 cm) Maximum Forward Reach (Boom Level) Curb-to-Curb Turning Circle: 4-Wheel Steering Ground Clearance Fording Depth Maximum Travel Speeds: Empty Loaded 23 mph (37 kph) 15 mph (24 kph) 65 ft (19.8 m) 18 inch (45.7 cm) 60 inch (1.5 m) 20.6 ft (6.28 m)

END OF WORK PACKAGE

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0003

FIELD MAINTENANCE THEORY OF OPERATION

INTRODUCTION 1. The Rough Terrain Container Handler (RTCH) consists of the following major components and functional systems: drive train, fuel system, exhaust system, cooling system, electrical and electronic systems, steering and brake systems, hydraulic system, cab system, and lifting boom with tophandler. A forklift kit may be added as required. 2. This work package explains how the components and systems of the RTCH work together. A functional description is provided for each major component and system. DRIVE TRAIN 1. The engine is a six-cylinder turbocharged diesel which supplies power to the transmission. The engine cooling system is pressurized and includes a thermostat, controlled bypass, and coolant expansion tank. Engine lubrication is pressurized and full-flow filters continuously clean oil. 2. The transmission is a semi-automatic electronically-controlled unit. The operator electronically selects range of gears and the transmission electronic control module (ECM) controls shift points up to the highest selected gear. A shift inhibitor circuit controls downshifts in forward and reverse gears. The transmission can be manually or electronically shifted through 4 forward and 3 reverse gears. A torque converter provides interface to the engine. 3. The driveshafts transmit rotation of the transmission output to the front and rear axles. Connections at both ends are made through universal joints to compensate for any misalignment due to operating on uneven surfaces. 4. The front and rear axles are identical in operating principles. Both axles are hydraulically steered with planetary wheel ends and wet-disc brakes. The rear axle oscillates above and below horizontal to allow for operation on uneven surfaces. FUEL SYSTEM 1. Fuel to power the engine is pumped from the fuel tank by a fuel transfer pump to the electronically controlled fuel injector nozzles. 2. The engine ECM manages, monitors, and stores key engine functions, to include engine idle speed, limits maximum engine speed, and engine diagnostic data. 3. The engine-mounted fuel/water separator is a spin-on replaceable type with drain. EXHAUST SYSTEM The exhaust system removes exhaust gases from the engine through the exhaust manifold and turbocharger. The gases flow into exhaust pipes and muffler to the atmosphere along the right side and to the rear of the operator's cab. COOLING SYSTEM 1. The cooling system consists of an engine-mounted circulating pump, 180 to 200F (82 to 93C) thermostat, oil cooler/aftercooler manifolds, a radiator, engine-mounted coolant filter, and hydraulically-driven cooling fan. 2. The cooling system cools the engine by means of circulating pressurized ethylene glycol-based coolant through the engine and radiator.

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0003

ELECTRICAL SYSTEM 1. The system voltage is 24V. Four 12V batteries, connected in series-parallel and charged by an alternator across electronic rectifying and voltage stabilization circuits, provide the voltage. 2. The negative and positive poles are both connected across the master battery switch. The negative pole is connected to the chassis. 3. NATO slave-starting receptacles are provided. STEERING SYSTEM 1. The electro-hydraulic steering system provides three modes of steering control: 2-wheel steer, 4-wheel steer, and crab steer. 2. The variable rate steering system utilizes two front and two rear hydraulic steering cylinders and electronic wheel position sensors connected to an ECM to maintain direction and control. The variable rate system allows the system to change or adjust to different modes of operation. 3. An emergency steering pump is provided in the event the engine is inoperative. If the engine quits while operating the RTCH, the emergency steering pump provides sufficient hydraulic pressure to control the RTCH until it is brought to a safe stop. BRAKE SYSTEM 1. The brakes are totally enclosed within the front and rear drive axle housings, next to the wheel ends. 2. The brake system is a wet brake system that is comprised of three separate hydraulic circuits: service brake circuit, cooling circuit, and parking brake circuit. 3. The brake system also includes six pressurized accumulators that provide adequate stored energy to stop the RTCH in the event of engine shutdown. 4. The service brake circuit is applied by depressing either the left or right floor-mounted hydraulic brake pedals. Brake pressure is applied to eight cylinders per side within the front axle and one cylinder per side in the rear axle. 5. The brake system cooling circuit cools the brake disks using oil pumped from the main hydraulic system through brake chambers during operation. 6. The parking brake assemblies are mounted at the input flanges of the front and rear axles. The brakes are applied by spring pressure and released hydraulically. A warning buzzer sounds if the driver leaves the seat without applying the parking brakes. The parking brake should never be applied as an emergency brake or while the vehicle is moving. Application of the parking brake while the vehicle is moving can result in major drive train damage. HYDRAULIC SYSTEM 1. The RTCH hydraulic system is comprised of the following major components that provide hydraulic power to operate and control the container tophandler, boom, steering, and brake systems. In addition the hydraulic system is used to place the cab and bogie wheels into transport mode. a. Three variable piston-type hydraulic pumps are driven by the transmission power take-off (PTO). The pumps provide hydraulics for the steering system and tophandler. b. One double vane-type pump is driven by the transmission PTO. It provides hydraulics for the boom cylinders, service, and parking brake systems. c. One single-vane pump is driven by the engine. It provides hydraulics for a cooling fan. d. Main valves control the main hydraulics. The valves are controlled by an electro-hydraulic servo system from the joystick control in the operator's cab. e. High-pressure oil filters clean hydraulic oil before returning oil to the reservoir. Breather filters allow venting of the hydraulic reservoir. f. Hydraulic system oil cooler and fan maintain and control hydraulic oil temperature. The cooling fan is powered by hydraulics from an engine-driven hydraulic pump. g. Emergency systems: one ground-driven hydraulic pump maintains steering control in the event of engine failure; a 24V electric hydraulic pump provides power to lower boom and release the twist

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HYDRAULIC SYSTEM - Continued locks in the event of engine failure. The electric pump also provides a means to place the operator's cab into the transport mode. CAB SYSTEM 1. The operator's cab is a sound and weather insulated unit that provides the operator with the systems to control and monitor both standard automotive functions and container handling functions. The following components or systems are also contained within the cab: a. Adjustable steering column and adjustable suspension seat. b. Heater, air conditioning, and filtered ventilation system. c. Portable fire extinguisher and rifle mount. AIR CONDITIONING SYSTEM The air conditioning system unit is part of the heater and is mounted at the front of the cab. It is a single unit consisting of a heater core, air conditioning evaporator coil, blower motor, control valves, and air ducts. The system is turned on by the air conditioning control switch on the instrument panel in the cab. The three-speed blower switch controls flow rate. An even cab temperature is maintained by using the air conditioner temperature control switch to control the refrigerant flow through the evaporator coil. ELECTRONIC SYSTEM The RTCH is equipped with several electronic modules, all connected using CAN-BUS technology. The modules can be diagnosed using the OEM testing equipment. They assist in the operation of major systems such as engine, transmission shifting, steering mode and wheel position, the safe working load control, and many related functions that require data input to operate correctly for the intended uses of the RTCH. LIFTING BOOM AND TOPHANDLER The lifting boom and tophandler is an electro-hydraulic operated heavy-duty telescoping boom and spreader assembly, designed to lift, move, and stack/unstack 20 to 40 ft (6.10 to 12.19 m) ISO containers. The operator joystick provides complete control of the lifting boom and tophandler during container handling operations. The boom provides lifting/lowering, extending/retracting operations. The tophandler or spreader provides for sideshifting, rotation, forward/rear tilting, left/right tilting, and load leveling and locking operations. The tophandler also provides interface capability with a forklift attachment. FORKLIFT KIT The forklift kit is attached to the tophandler twistlocks and two hydraulic hose quick-disconnects. Forklift operation is controlled from the tophandler joystick to include adjustable forktines. The forktines and vertical support beams fold under the forklift framework for transport. END OF WORK PACKAGE

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CHAPTER 2 TROUBLESHOOTING PROCEDURES

TM 10-3930-675-23-1

0004

FIELD MAINTENANCE ERROR CODE REFERENCES

EXPLANATION OF ERROR CODE DISPLAY

NOTE
There are three kinds of information in the Electronic Control System (ECS) display 1. Icons in the lower left corner of the display describe what the driver should do. Table 1 defines each of the three driver actions. Table 1. Driver Action Icons. ICON DESCRIPTION STOP VEHICLE IMMEDIATELY in a safe way. Can be a safety issue. Machine performance may be restricted. Read operators manual for instructions. Contact maintenance personnel. Any active Stop" type error code will de-rate the engine to 1,000 RPMs. The ignition must be shut off to clear the engine de-rate. Any engine temperature or oil pressure codes will de-rate the engine to 1,000 RPMs for 30 seconds and then shut the engine down. WARNING - DEGRADED OPERATION, stop vehicle in a safe way. Read operator's manual (TM 10-3930-675-10) for instructions. Contact maintenance personnel. Confirm that error message is acknowledged by pressing RESET button. Error will appear every three minutes as long as error is active. It can be reset every time it shows. INFORMATION/MAINTENANCE action is needed. Error code shows once when vehicle starts up. Acknowledge error message by pressing RESET. These error codes may be deactivated for driver, so that they only show when maintenance personnel activate them. RT 240V1R, RT 240V2 and RT 240V3. The information/maintenance icon will appear in the ECS display operational screen (weight/load center) to alert the maintenance personnel of potential service. 2. Icons in the center of the display identify the type of fault. Table 2 describes the five fault types used in the display. Table 2. ICON DESCRIPTION Sensor Type of Fault Icons. ICON DESCRIPTION Lever

Valve

Temperature

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0004

EXPLANATION OF ERROR CODE DISPLAY - Continued Table 2. ICON DESCRIPTION Pressure Type of Fault Icons - Continued. ICON DESCRIPTION

3. Icons in the right of the display identify what function or vehicle system the fault is related to. Table 3 lists the various functions or vehicle systems used in the display. Table 3. ICON DESCRIPTION Battery Function Icons. ICON DESCRIPTION Twistlock

Forklift Kit

Up/Down

Emergency Stop or Battery

In/Out

Rotation RT 240V1R, RT 240V2, and RT 240V3 only ECS display; lockout indication Hydraulic Filter

Transmission RT 240V1R, RT 240V2, and RT 240V3 ECS display; lockout indication Fan

Communication

Engine

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0004

EXPLANATION OF ERROR CODE DISPLAY - Continued Table 3. ICON DESCRIPTION Sideshifting Function Icons - Continued. ICON DESCRIPTION No Overload Protection

Oscillation (leveling)

Brake

Spreading

Tilt RT 240V1R, RT 240V2, and RT 240V3 ECS display; lockout indication

Steering

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0004

EXPLANATION OF ERROR CODE DISPLAY - Continued

Table 4. Error Code Reference Index. ERROR DISPLAY CODE LAYOUT 1 TROUBLESHOOTING PROCEDURE WORK PACKAGE (WP 0038) ERROR CODE CATEGORY/ EXPLANATION Information/Maintenance Lifting/lowering boom. Hydraulic filter clogged. Information/Maintenance Steering. Hydraulic filter clogged. Information/Maintenance Tophandler attachment. Hydraulic filter clogged. Information/Maintenance Return filter. Hydraulic filter clogged. Information/Maintenance Appears during replacement of ECU. Software not compatible with other software in system. VEHICLE LIMITATIONS None.

(WP 0038)

None.

(WP 0038)

None.

(WP 0038)

None.

103

(WP 0013)

Undesired functions and not relevant error codes may appear. Operating system not responding. Boom and tophandler may not work. Operating system not responding. Boom and tophandler may not work. No redundancy in ECS system of boom, display, and tophandler function

105

(WP 0013)

Stop Vehicle Immediately ECU 790 not responding. Circuit breaker tripped. Cable defective. ECU 790 defective.

106

(WP 0013)

Stop Vehicle Immediately ECU 791 not responding. Circuit breaker tripped. Cable defective. ECU 791 defective.

107

(WP 0013)

Information/Maintenance Communication, cable segment 1 between ECU 795 and 791. Cable between ECU 795 - 791 interrupted or short circuited.

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EXPLANATION OF ERROR CODE DISPLAY - Continued Table 4. ERROR DISPLAY CODE LAYOUT 108 Error Code Reference Index - Continued. ERROR CODE CATEGORY/ EXPLANATION Information/Maintenance Communication, cable segment 2 between ECU 791 and 790. Cable between ECU 791 - 790 interrupted or short circuited. Information/Maintenance Communication, cable segment 3 between ECU 790 and 795. Cable between ECU 790 - 795 interrupted or short circuited. VEHICLE LIMITATIONS No redundancy in ECS system of boom, display, and tophandler function. No redundancy in ECS system of boom, display, and tophandler function.

TROUBLESHOOTING PROCEDURE WORK PACKAGE (WP 0013)

109

(WP 0013)

110

(WP 0013)

Stop Vehicle Immediately Steering may not Communication, ECU 792 function properly. steering computer not responding. Circuit breaker tripped. Cable defective. ECU 792 defective. Stop Vehicle Immediately Transmission Communication, ECU 793 may not function transmission computer not properly responding. Circuit breaker tripped. Cable defective. ECU 793 defective. Stop Vehicle Immediately Engine may not ECU 794 - engine computer not function properly. responding. Circuit breaker tripped. Cable defective. ECU 794 defective. Stop Vehicle Immediately No pressure/signal - both brake systems. Circuit breaker tripped. Hydraulic failure. Warning - Degraded Operation No pressure - brake circuit 1. Hydraulic failure. Warning - Degraded Operation No pressure - brake circuit 2. Hydraulic failure. Brakes may not function properly.

111

(WP 0013)

112

(WP 0013)

118

(WP 0030)

119

(WP 0030)

Only half brake capability available. Only half brake capability available.

120

(WP 0030)

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0004

EXPLANATION OF ERROR CODE DISPLAY - Continued Table 4. ERROR DISPLAY CODE LAYOUT 121 Error Code Reference Index - Continued. ERROR CODE CATEGORY/ EXPLANATION Stop Vehicle Immediately Supply voltage - ECU 790. Emergency stop engaged. Circuit breaker tripped. Cable defective. Stop Vehicle Immediately Supply voltage - CAN 790. Circuit breaker tripped. Cable defective. VEHICLE LIMITATIONS Operating system and boom function not working. Operating system and boom function not working. Operating system and boom function not working. None if code clears. Operating system and boom function not working. Lift/lower does not function properly (hydraulic stops).

TROUBLESHOOTING PROCEDURE WORK PACKAGE (WP 0012)

122

(WP 0012)

123

(WP 0012)

Stop Vehicle Immediately Ref. voltages 10V - ECU 790. Circuit breaker tripped. Cable defective. Stop Vehicle Immediately Memory fault, check ECU 790. Circuit breaker tripped. Cable defective.

125

(WP 0035)

126

(WP 0039)

Stop Vehicle Immediately Signal for lifting/lowering, out of range. Cable defective. Short circuit. Potentiometer in joystick not functioning. Stop Vehicle Immediately Signal for boom in/out, out of range. Cable defective. Short circuit. Potentiometer in joystick not functioning. Stop Vehicle Immediately Signal for slewing, out of range. Cable defective. Short circuit. Potentiometer in joystick not functioning. Stop Vehicle Immediately Signal for tilt in/out, out of range. Cable defective. Short circuit. Potentiometer in joystick not functioning.

127

(WP 0040)

Boom in/out does not function properly (hydraulic stops).

128

(WP 0043)

Slewing does not function properly (hydraulic stops).

129

(WP 0042)

Tilt does not function properly (hydraulic stops).

0004-6

03/15/2011 Rel(1.8) root(tsindxwp) wpno(T00009)

TM 10-3930-675-23-1

0004

EXPLANATION OF ERROR CODE DISPLAY - Continued Table 4. ERROR DISPLAY CODE LAYOUT 130 Error Code Reference Index - Continued. ERROR CODE CATEGORY/ EXPLANATION Stop Vehicle Immediately Overload protection error. Error codes 131 - 136 or 210 have been active. Stop Vehicle Immediately Boom sensor - boom length out of range or no signal change when boom is moving. Cable defective. Short circuit. Potentiometer damaged. Hydraulic failure. Stop Vehicle Immediately Boom sensor - boom angle out of range or no signal change when lowering/lifting boom. Sensor bracket or lever damaged. Cable defective. Short circuit. Potentiometer damaged. Hydraulic failure. Stop Vehicle Immediately Left lift cylinder pressure sensor, signal out of range. Cable defective. Short circuit. Pressure sensor defective. Stop Vehicle Immediately Right lift cylinder pressure sensor, signal out of range. Cable defective. Short circuit. Pressure sensor defective. Stop Vehicle Immediately Left lift cylinder return pressure sensor, signal out of range. Cable defective. Short circuit. Pressure sensor defective. VEHICLE LIMITATIONS No overload protection system. Reduced hydraulic speed. No overload protection system. Reduced hydraulic speed.

TROUBLESHOOTING PROCEDURE WORK PACKAGE (WP 0042)

131

(WP 0010)

132

(WP 0010)

No overload protection system. Reduced hydraulic speed.

133

(WP 0010)

No overload protection system. Reduced hydraulic speed.

134

(WP 0010)

No overload protection system. Reduced hydraulic speed.

135

(WP 0010)

Stop Vehicle Immediately Left lift cylinder return pressure sensor, signal out of range. Cable defective. Short circuit. Pressure sensor defective. Pressure sensor, signal out of range Cable defective. Short

136

(WP 0010)

Stop Vehicle Immediately Right lift cylinder return pressure sensor, signal out of range. Cable

0004-7

03/15/2011 Rel(1.8) root(tsindxwp) wpno(T00009)

TM 10-3930-675-23-1

0004

EXPLANATION OF ERROR CODE DISPLAY - Continued Table 4. ERROR DISPLAY CODE LAYOUT Error Code Reference Index - Continued. ERROR CODE CATEGORY/ EXPLANATION defective. Short circuit. Pressure sensor defective. VEHICLE LIMITATIONS circuit. Pressure sensor defective. No overload protection system. Reduced hydraulic speed. Possible ECU malfunction. Other codes will also show. Possible ECU malfunction. Other codes will also show. Boom cannot be lowered with joystick. Emergency lowering is necessary. Boom cannot be lowered with joystick. Emergency lowering is necessary. Lifting is impossible.

TROUBLESHOOTING PROCEDURE WORK PACKAGE

141

(WP 0035)

Information/Maintenance Communication fault - ECU 790. Computer hardware fault.

142

(WP 0035)

Information/Maintenance Communication fault - ECU 790. Computer hardware fault.

151

(WP 0039)

Stop Vehicle Immediately Locking valve, broken circuit. Cable to valve defective.

152

(WP 0039)

Stop Vehicle Immediately Locking valve, short circuit. Cable to valve defective.

154

(WP 0039)

Stop Vehicle Immediately Lifting valve, broken circuit. Cable to valve defective.

155

(WP 0039)

Stop Vehicle Immediately Uncontrolled selfLifting valve, short circuit. Cable to lifting may occur. valve defective. Stop Vehicle Immediately Lowering valve, broken circuit. Cable to valve defective. Boom cannot be lowered with joystick. Emergency lowering is necessary.

157

(WP 0039)

0004-8

03/15/2011 Rel(1.8) root(tsindxwp) wpno(T00009)

TM 10-3930-675-23-1

0004

EXPLANATION OF ERROR CODE DISPLAY - Continued Table 4. ERROR DISPLAY CODE LAYOUT 158 Error Code Reference Index - Continued. ERROR CODE CATEGORY/ EXPLANATION VEHICLE LIMITATIONS

TROUBLESHOOTING PROCEDURE WORK PACKAGE (WP 0039)

Stop Vehicle Immediately Boom cannot be Lowering valve, short circuit. Cable lowered with to valve defective. joystick. Emergency lowering is necessary. Uncontrolled selflifting may occur. Stop Vehicle Immediately Boom in valve, broken circuit. Cable to valve defective. Boom cannot be retracted.

160

(WP 0040)

161

(WP 0040)

Stop Vehicle Immediately Boom cannot be Boom in valve, short circuit. Cable retracted. to valve defective. Uncontrolled selfretraction may occur. Stop Vehicle Immediately Boom out valve, broken circuit. Cable to valve defective. Stop Vehicle Immediately Boom out valve, short circuit. Cable to valve defective. Boom cannot be extended.

163

(WP 0040)

164

(WP 0040)

Boom cannot be extended. Uncontrolled selfextension may occur. Cooling fan will run at full speed. No fording activities possible. Cooling fan may run at any speed. No fording activities possible. Overheating may occur. No hydraulic emergency operation is possible.

166

(WP 0009)

Warning - Degraded Operation Cooling fan valve, broken circuit. Cable to valve defective.

167

(WP 0009)

Warning - Degraded Operation Cooling fan valve, short circuit. Cable to valve defective.

169

(WP 0036)

Warning - Degraded Operation Emergency hydraulic valve, broken circuit. Cable to valve defective.

0004-9

03/15/2011 Rel(1.8) root(tsindxwp) wpno(T00009)

TM 10-3930-675-23-1

0004

EXPLANATION OF ERROR CODE DISPLAY - Continued Table 4. ERROR DISPLAY CODE LAYOUT 172 Error Code Reference Index - Continued. ERROR CODE CATEGORY/ EXPLANATION VEHICLE LIMITATIONS

TROUBLESHOOTING PROCEDURE WORK PACKAGE (WP 0037)

Information/Maintenance May be difficult to Pump turn off valve, broken circuit. start because of Cable defective. engaged pumps. Stop Vehicle Immediately Temperature in front wheel end above 203F (95C). Cable defective. No cooling. Stop Vehicle Immediately Temperature in rear wheel end above 203F (95C) Cable defective. No cooling. Stop Vehicle Immediately Supply voltage, ECU 791. Emergency stop engaged. Circuit breaker tripped. Cable defective. Stop Vehicle Immediately Supply voltage, CAN 791. Circuit breaker tripped. Cable defective. Brakes may overheat at front axle.

191

(WP 0031)

192

(WP 0031)

Brakes may overheat at rear axle.

201

(WP 0012)

Tophandler not working.

202

(WP 0012)

Operating system and tophandler not working. Operating system not working. None if code clears. Operating system and tophandler not working. Generate error code 130.

203

(WP 0012)

Stop Vehicle Immediately Ref. voltages 10V-791/ Circuit breaker tripped. Cable defective. Stop Vehicle Immediately Memory fault - check ECU 791. Circuit breaker tripped. Cable defective.

205

(WP 0011)

210

(WP 0010)

Stop Vehicle Immediately Tilt angle sensor, signal out of range. Potentiometer damaged. Cable defective. Short circuit. Stop Vehicle Immediately Logical error - left twistlock. Short circuit. Signal from both 7204L and 7205L.

212

(WP 0046)

Both locked and unlocked twistlock at the same time. Safe operation is not possible.

0004-10

03/15/2011 Rel(1.8) root(tsindxwp) wpno(T00009)

TM 10-3930-675-23-1

0004

EXPLANATION OF ERROR CODE DISPLAY - Continued Table 4. ERROR DISPLAY CODE LAYOUT 213 Error Code Reference Index - Continued. ERROR CODE CATEGORY/ EXPLANATION Stop Vehicle Immediately Logical error - right twistlock. Short circuit. Signal from both 7204R and 7205R. VEHICLE LIMITATIONS Both locked and unlocked twistlock at the same time. Safe operation is not possible. Operation of forklift is not possible.

TROUBLESHOOTING PROCEDURE WORK PACKAGE (WP 0046)

214

(WP 0046)

Stop Vehicle Immediately Logical error - forklift sensors. Cable defective. Signal from 7206-1 or 7206-2. Warning - Degraded Operation One pulse signal to the steering wheel interrupted. Clock 1. Clock 2.

220

(WP 0011)

Stop vehicle by switching to neutral. Steering system will operate but is not redundant. The steering computer uses non interrupted signal to steer the vehicle. Possible ECU malfunction. Other codes will also show.

221

(WP 0011)

Information/Maintenance Communication fault - ECU 791, connector 2. Computer hardware fault.

225

(WP 0044)

Warning - Degraded Operation Left sideshift is Left sideshift, open circuit. Cable to not possible. valve defective. Warning - Degraded Operation Uncontrolled left Left sideshift, short circuit. Cable to sideshift may valve defective. occur. Warning - Degraded Operation Right sideshift is Right sideshift, open circuit. Cable not possible. to valve defective. Warning - Degraded Operation Uncontrolled Right sideshift, short circuit. Cable right sideshift to valve defective. may occur.

226

(WP 0044)

228

(WP 0044)

229

(WP 0044)

0004-11

03/15/2011 Rel(1.8) root(tsindxwp) wpno(T00009)

TM 10-3930-675-23-1

0004

EXPLANATION OF ERROR CODE DISPLAY - Continued Table 4. ERROR DISPLAY CODE LAYOUT 231 Error Code Reference Index - Continued. ERROR CODE CATEGORY/ EXPLANATION VEHICLE LIMITATIONS

TROUBLESHOOTING PROCEDURE WORK PACKAGE (WP 0045)

Warning - Degraded Operation Spreading from 20 to 40 valve, open circuit. Cable 20 to 40 ft is not to valve defective. possible. Warning - Degraded Operation Spreading from 20 to 40 valve, short circuit. Cable 20 to 40 ft is not to valve defective. possible. Warning - Degraded Operation Spreading from 40 to 20 valve, open circuit. Cable 40 to 20 ft is not to valve defective. possible. Warning - Degraded Operation Spreading from 40 to 20 valve, short circuit. Cable 20 to 40 ft is not to valve defective. possible. Warning - Degraded Operation Tophandler Active tilt valve, open circuit. Cable locked, not to valve defective. automatically leveled. Warning - Degraded Operation Active pile slope, open circuit. Cable to valve defective. Warning - Degraded Operation Twistlock valve lock, open circuit. Cable to valve defective. Warning - Degraded Operation Twistlock valve unlock, open circuit. Cable to valve defective. Information/Maintenance Communication fault - ECU 791, connector 3. Computer hardware fault. Information/Maintenance Communication fault - ECU 791, connector 3. Computer hardware fault. Warning - Degraded Operation Slewing clockwise valve, open circuit. Cable to valve defective. Tophandler locked, not free oscillated. Impossible to lock twistlock.

232

(WP 0045)

234

(WP 0045)

235

(WP 0045)

237

(WP 0042)

240

(WP 0043)

243

(WP 0046)

246

(WP 0046)

Impossible to unlock twistlock.

250

(WP 0011)

Possible ECU malfunction. Other codes will also show. Possible ECU malfunction. Other codes will also show. Slewing clockwise is not possible.

251

(WP 0011)

255

(WP 0041)

0004-12

03/15/2011 Rel(1.8) root(tsindxwp) wpno(T00009)

TM 10-3930-675-23-1

0004

EXPLANATION OF ERROR CODE DISPLAY - Continued Table 4. ERROR DISPLAY CODE LAYOUT 256 Error Code Reference Index - Continued. ERROR CODE CATEGORY/ EXPLANATION Warning - Degraded Operation Slewing clockwise valve, short circuit. Cable to valve defective. Warning - Degraded Operation Slewing counterclockwise valve, open circuit. Cable to valve defective. Warning - Degraded Operation Slewing counterclockwise valve, short circuit. Cable to valve defective. VEHICLE LIMITATIONS Uncontrolled slewing may occur. Slewing clockwise is not possible.

TROUBLESHOOTING PROCEDURE WORK PACKAGE (WP 0041)

258

(WP 0041)

259

(WP 0041)

Uncontrolled slewing may occur.

261

(WP 0042)

Warning - Degraded Operation Tilt out is not Tilt out valve, open circuit. Cable to possible. valve defective. Warning - Degraded Operation Uncontrolled tilt Tilt out valve, short circuit. Cable to may occur. valve defective. Warning - Degraded Operation Tilt in valve, open circuit. Cable to valve defective. Warning - Degraded Operation Tilt in valve, short circuit. Cable to valve defective. Tilt in is not possible.

262

(WP 0042)

264

(WP 0042)

265

(WP 0042)

Uncontrolled tilt may occur.

267

(WP 0043)

Warning - Degraded Operation Right oscillation Right oscillation valve, open circuit. (leveling) is not Cable to valve defective. possible. Warning - Degraded Operation Uncontrolled Right oscillation valve, short circuit. oscillation Cable to valve defective. (leveling) may occur. Warning - Degraded Operation Left oscillation valve, open circuit. Cable to valve defective. Warning - Degraded Operation Left oscillation (leveling) is not possible. Uncontrolled oscillation

268

(WP 0043)

270

(WP 0043)

271

(WP 0043)

0004-13

03/15/2011 Rel(1.8) root(tsindxwp) wpno(T00009)

TM 10-3930-675-23-1

0004

EXPLANATION OF ERROR CODE DISPLAY - Continued Table 4. ERROR DISPLAY CODE LAYOUT Error Code Reference Index - Continued. ERROR CODE CATEGORY/ EXPLANATION VEHICLE LIMITATIONS

TROUBLESHOOTING PROCEDURE WORK PACKAGE

Left oscillation valve - short circuit. (leveling) may Cable to valve defective occur. 300 (WP 0014) Stop Vehicle Immediately Steering system malfunction. Steering computer - hardware error (EEPROM, watchdog, reference voltages, etc.) No steering or driving functions are available. Reduced power and engine speed. Stop vehicle by switching to NEUTRAL. Steering system will operate but is not redundant.

301 302 303 304 305 306 307 308

(WP 0034)

Warning - Degraded Operation One track of actual value potentiometer out of range (e.g., cable interrupted). Wheel 1, track 1. Wheel 2, track 1. Wheel 3, track 1. Wheel 4, track 1. Wheel 1, track 2. Wheel 2, track 2. Wheel 3, track 2. Wheel 4, track 2. Stop Vehicle Immediately Both tracks of actual value potentiometer out of range. Wheel 1. Wheel 2. Wheel 3. Wheel 4.

309 310 311 312

(WP 0034)

Stop vehicle by switching to NEUTRAL. Faulty wheel is locked immediately. Other wheels remain operational. Reduced power and engine speed. Stop vehicle by switching to NEUTRAL. Steering system will operate but is not redundant. Reduced power and engine speed.

313 314 315 316

(WP 0034)

Stop Vehicle Immediately Deviation between two potentiometer tracks, but both inside tolerance range. Wheel 1. Wheel 2. Wheel 3. Wheel 4.

0004-14

03/15/2011 Rel(1.8) root(tsindxwp) wpno(T00009)

TM 10-3930-675-23-1

0004

EXPLANATION OF ERROR CODE DISPLAY - Continued Table 4. ERROR DISPLAY CODE LAYOUT 317 318 319 320 Error Code Reference Index - Continued. ERROR CODE CATEGORY/ EXPLANATION Stop Vehicle Immediately Steering deviation between set point and actual value (tracking error). Wheel 1. Wheel 2. Wheel 3. Wheel 4. VEHICLE LIMITATIONS Stop vehicle by switching to NEUTRAL. Steering remains active and tries to close up to set point. System will be active as soon as deviating wheel has closed up. Reduced power and engine speed. This error prohibits driving after steering calibration if calibration was not successful or calibration values are out of range. Reduced power and engine speed. Stop vehicle by switching to NEUTRAL. Steering computer cannot control wheel with broken cable. Faulty wheel has to be aligned by manual operation of valve. Reduced power and engine speed. Stop vehicle by switching to NEUTRAL. Steering computer cannot control wheel

TROUBLESHOOTING PROCEDURE WORK PACKAGE (WP 0033)

321 322 323 324

(WP 0033)

Stop Vehicle Immediately Wheel alignment values out of range. Wheel 1. Wheel 2. Wheel 3. Wheel 4.

325 326 327 328

(WP 0032)

Stop Vehicle Immediately Break in cable to proportional valve. Wheel 1. Wheel 2. Wheel 3. Wheel 4.

329 330 331

(WP 0032)

Stop Vehicle Immediately Cable to proportional valve - short circuit. Wheel 1. Wheel 2. Wheel 3.

0004-15

03/15/2011 Rel(1.8) root(tsindxwp) wpno(T00009)

TM 10-3930-675-23-1

0004

EXPLANATION OF ERROR CODE DISPLAY - Continued Table 4. ERROR DISPLAY CODE LAYOUT 332 Error Code Reference Index - Continued. ERROR CODE CATEGORY/ EXPLANATION Wheel 4. VEHICLE LIMITATIONS with broken cable. Faulty wheel has to be aligned by manual operation of valve. Reduced power and engine speed. Steering system out of order. No steering or driving functions are available. Stop vehicle by switching to NEUTRAL. Steering system will operate in a degraded mode. Stop vehicle by switching to NEUTRAL. Steering system will operate but is not redundant. Steering computer uses one of two counters to steer vehicle. Reduced power and engine speed. Stop vehicle by switching to NEUTRAL. Steering system will operate but is not redundant. Steering computer uses uninterrupted

TROUBLESHOOTING PROCEDURE WORK PACKAGE

339

(WP 0032)

Stop Vehicle Immediately Steering wheel sensor malfunction. Possible loss of ground.

340

(WP 0032)

Warning - Degraded Operation Supply pressure below 1450 psi (100 bar). Leaking hydraulics.

341

(WP 0032)

Stop Vehicle Immediately Steering wheel signals inconsistent (e.g., two incremental counters deviating). Cables defective. Steering column sensor defective.

342

(WP 0032)

Warning - Degraded Operation

0004-16

03/15/2011 Rel(1.8) root(tsindxwp) wpno(T00009)

TM 10-3930-675-23-1

0004

EXPLANATION OF ERROR CODE DISPLAY - Continued Table 4. ERROR DISPLAY CODE LAYOUT 343 Error Code Reference Index - Continued. ERROR CODE CATEGORY/ EXPLANATION VEHICLE LIMITATIONS

TROUBLESHOOTING PROCEDURE WORK PACKAGE

One pulse signal to steering wheel signal to steer interrupted. Cables defective. vehicle. Steering column sensor defective. (WP 0032) Stop Vehicle Immediately Both pulse signals to steering wheel interrupted. Cables defective. Steering column sensor defective. Stop vehicle by switching to NEUTRAL. Steering system will not operate. Reduced power and engine speed.

344

345

(WP 0013)

Warning - Degraded Operation Error codes from No CAN communication to display. steering ECU will Cable defective. not show on display. Steering function is operational. Warning - Degraded Operation No CAN communication to transmission. Cables defective. It is not possible to change from 2WD to 4WD or vice versa. Steering system remains operational, but steering features dependent on driving speed are not available. To keep vehicle in full operation, steering program selection is allowed at this time. None.

346

(WP 0013)

347

(WP 0032)

Information/Maintenance No valid steering program selected. Stop Vehicle Immediately Steering valve solenoid.

350 351 352

(WP 0016)

Stop vehicle by switching to NEUTRAL. Steering system

0004-17

03/15/2011 Rel(1.8) root(tsindxwp) wpno(T00009)

TM 10-3930-675-23-1

0004

EXPLANATION OF ERROR CODE DISPLAY - Continued Table 4. ERROR DISPLAY CODE LAYOUT 353 Error Code Reference Index - Continued. ERROR CODE CATEGORY/ EXPLANATION This error code occurs if the solenoid or circuit resistance differs from the preset value. (WP 0016) Stop Vehicle Immediately Start-up failure in steering system. This error code is caused by incorrect parameter settings in steering computer. VEHICLE LIMITATIONS will not operate properly.

TROUBLESHOOTING PROCEDURE WORK PACKAGE

354 355 356 357

Stop vehicle by switching to NEUTRAL. Steering system will not operate properly. Fully operational. History storage of error codes may not be possible.

399

(WP 0016)

Warning - Degraded Operation EEPROM parameter error in steering computer. One or more parameter values inside EEPROM are out of range.

401

(WP 0016)

Warning - Degraded Operation Transmission will Digital output short circuit - Enable not go into neutral driving" (no neutral gear from automatically. steering ECU). Cables defective. Information/Maintenance Digital output short circuit - Control lamp, front wheel steering." Cables defective. Information/Maintenance Digital output short circuit - Control lamp, four wheel steering." Cables defective. Information/Maintenance Digital output short circuit - Control lamp, crab steering" Cables defective. Control lamp on steering selection switch is not working. Control lamp on steering selection switch is not working. Control lamp on steering selection switch is not working.

404

(WP 0016)

405

(WP 0016)

406

(WP 0016)

408

(WP 0016)

Information/Maintenance Control lamp on Digital output short circuit - Control steering column lamp, unlocked twistlock." Cables is not working. defective. Information/Maintenance Control lamp on Digital output short circuit - Control steering column lamp, locked twistlock." Cables is not working. defective.

409

(WP 0016)

0004-18

03/15/2011 Rel(1.8) root(tsindxwp) wpno(T00009)

TM 10-3930-675-23-1

0004

EXPLANATION OF ERROR CODE DISPLAY - Continued Table 4. ERROR DISPLAY CODE LAYOUT 410 Error Code Reference Index - Continued. ERROR CODE CATEGORY/ EXPLANATION VEHICLE LIMITATIONS

TROUBLESHOOTING PROCEDURE WORK PACKAGE (WP 0016)

Information/Maintenance Control lamp on Digital output short circuit - Control steering column lamp, alignment." Cables is not working. defective. Information/Maintenance Digital output short circuit Auxiliary hydraulic pump." Cables defective. Cab cannot be moved. No emergency operation of boom or tophandler available. Ether start not working.

411

(WP 0036)

412

(WP 0016)

Information/Maintenance Digital output short circuit - Ether start kit." Cables defective. Information/Maintenance Digital output short circuit - Oil supply valve, boom folding." Cables defective. Warning - Degraded Operation Digital output short circuit - Drive axle cooling, bypass valves." Cables defective.

413

(WP 0016)

Boom cannot be folded.

414

(WP 0031)

Brakes may be overheated. Error codes 191 and 192 will show if brakes have overheated. Reduced power and engine speed. Steering pressure failure cannot be detected, error code 340. Auxiliary hydraulic pump cannot be started.

415

(WP 0016)

Stop Vehicle Immediately Digital output short circuit.

416

(WP 0016)

Stop Vehicle Immediately Digital input not read correctly Steering pressure." Cables defective.

417

(WP 0036)

Information/Maintenance Digital input not read correctly Auxiliary hydraulic pump switch." Cables defective.

0004-19

03/15/2011 Rel(1.8) root(tsindxwp) wpno(T00009)

TM 10-3930-675-23-1

0004

EXPLANATION OF ERROR CODE DISPLAY - Continued Table 4. ERROR DISPLAY CODE LAYOUT 418 Error Code Reference Index - Continued. ERROR CODE CATEGORY/ EXPLANATION Warning - Degraded Operation Digital input not read correctly Front wheel steering switch." Cables defective. Warning - Degraded Operation Digital input not read correctly Four wheel steering switch" Cables defective. Warning - Degraded Operation Digital input not read correctly Crab steering switch." Cables defective. VEHICLE LIMITATIONS 2WD cannot be selected.

TROUBLESHOOTING PROCEDURE WORK PACKAGE (WP 0016)

419

(WP 0016)

4WD cannot be selected.

420

(WP 0016)

Crab steering cannot be selected.

422

(WP 0016)

Information/Maintenance Boom folding is Digital input not read correctly not possible. Sensor, cab in transport position." Cables defective. Steering computer damaged. Information/Maintenance Digital input not read correctly Ether start switch." Cables defective. Steering computer damaged. Warning - Degraded Operation Digital input not read correctly Fording level switch." Cables defective. Steering computer damaged. Information/Maintenance Digital input not read correctly Tophandler work light switch." Cables defective. Steering computer damaged. Information/Maintenance Digital input not read correctly Hydraulic filter indication (lift/ lower; boom in/out)." Cables defective. Steering computer damaged. Ether injection is not possible.

423

(WP 0016)

426

(WP 0009)

Fording operations are not possible.

427

(WP 0016)

Work lights on tophandler do not function.

432

(WP 0038)

None.

0004-20

03/15/2011 Rel(1.8) root(tsindxwp) wpno(T00009)

TM 10-3930-675-23-1

0004

EXPLANATION OF ERROR CODE DISPLAY - Continued Table 4. ERROR DISPLAY CODE LAYOUT 433 Error Code Reference Index - Continued. ERROR CODE CATEGORY/ EXPLANATION Information/Maintenance Digital input not read correctly Hydraulic filter indication, steering." Cables defective. Steering computer damaged. Information/Maintenance Digital input not read correctly Hydraulic filter indication, tophandler." Cables defective. Steering computer damaged. Information/Maintenance Digital input not read correctly Hydraulic filter indication, return oil." Cables defective. Steering computer damaged. Information/Maintenance Error on power supply for steering wheel sensor error code can be caused by: Short circuit of analog output terminal 38 to +24V. Short circuit of analog output terminal 38 to ground. Fault in steering computer output. Warning - Degraded Operation Ambient temperature too high. Temperature sensor defective. ECU 792 defective. VEHICLE LIMITATIONS None.

TROUBLESHOOTING PROCEDURE WORK PACKAGE (WP 0038)

434

(WP 0038)

None.

435

(WP 0038)

None.

440

(WP 0016)

Steering wheel has no end positions or steering resistance.

450

(WP 0016)

None.

451

(WP 0015)

Warning - Degraded Operation Stop vehicle by Supply voltage too high. Alternator switching to defective. neutral. Warning - Degraded Operation Supply voltage too low. Power supply off. Alternator defective Stop Vehicle Immediately Supply voltage for wheel sensors out of range. The +5 supply voltage for angle transducer track 2 is too low. Error code can be caused by short circuit Stop vehicle by switching to neutral The vehicle is stopped by switching to neutral gear. If error code 454 is also active, all

452

(WP 0015)

453

(WP 0015)

0004-21

03/15/2011 Rel(1.8) root(tsindxwp) wpno(T00009)

TM 10-3930-675-23-1

0004

EXPLANATION OF ERROR CODE DISPLAY - Continued Table 4. ERROR DISPLAY CODE LAYOUT Error Code Reference Index - Continued. ERROR CODE CATEGORY/ EXPLANATION VEHICLE LIMITATIONS

TROUBLESHOOTING PROCEDURE WORK PACKAGE

in one or more angle transducer wheels are tracks or low impedance to ground. locked. 454 (WP 0015) Stop Vehicle Immediately Supply voltage for wheel sensors out of range. The +5 supply voltage for angle transducer track 1 is too low. Error code can be caused by short circuit in one or more angle transducer tracks or low impedance to ground. Warning - Degraded Operation Logical error at direction select signal - transmission ECU detected incorrect signal combination for the direction. Cables defective. Shift lever defective. Information/Maintenance Logical error at axle connection axle connection feedback measured by transmission ECU and output signal do not match. Cables defective. Switch defective. Mechanical error. The vehicle is stopped by switching to neutral gear. If error code 454 is also active, all wheels are locked. Stop vehicle by switching to neutral.

618

(WP 0028)

622

(WP 0028)

When shifting from 2WD to 4WD or vice versa, engage forward drive and immediately return to neutral. Turn the ignition switch off for at least 30 seconds, then turn switch back on.

637

(WP 0025)

Information/Maintenance None. Short circuit to battery voltage or open circuit at transmission sump temperature sensor input - voltage too high. Cables defective. Sensor defective. Connector pin broken. Information/Maintenance Short circuit to ground at transmission sump temperature sensor input - voltage too low. Cables defective. Sensor defective. Connector pin broken. None.

638

(WP 0025)

0004-22

03/15/2011 Rel(1.8) root(tsindxwp) wpno(T00009)

TM 10-3930-675-23-1

0004

EXPLANATION OF ERROR CODE DISPLAY - Continued Table 4. ERROR DISPLAY CODE LAYOUT 639 Error Code Reference Index - Continued. ERROR CODE CATEGORY/ EXPLANATION VEHICLE LIMITATIONS

TROUBLESHOOTING PROCEDURE WORK PACKAGE (WP 0025)

Information/Maintenance None. Short circuit to battery voltage or open circuit at converter output temperature sensor input - voltage too low. Cables defective. Sensor defective. Connector pin broken. Information/Maintenance None. Short circuit to battery voltage or open circuit at converter output temperature sensor input - voltage too low. Cables defective. Sensor defective. Connector pin broken. Information/Maintenance Short circuit to battery voltage or open circuit at engine speed input - transmission ECU measures a voltage higher than 7.0V at speed input pin. Cables defective. Sensor defective. Connector pin broken. Information/Maintenance Short circuit to ground at engine speed input - transmission ECU measures a voltage less than 0.45V at speed input pin. Cables defective. Sensor defective. Information/Maintenance Logical error at engine speed input - transmission ECU measures engine speed over a threshold and the next moment the measured speed is zero. Cables defective. Sensor defective. Incorrect sensor gap size. Warning - Degraded Operation Short circuit to battery voltage or open circuit at turbine speed input - transmission ECU measures a voltage higher than 7.0V at speed input pin. Cables defective. Sensor Gearshift quality is reduced, due to another control mode (operating mode: substitute clutch control).

640

(WP 0025)

649

(WP 0026)

650

(WP 0026)

Gearshift quality is reduced, due to another control mode (operating mode: substitute clutch control). Gearshift quality is reduced, due to another control mode (operating mode: substitute clutch control).

651

(WP 0026)

652

(WP 0026)

Gearshift quality is reduced, due to another control mode (operating mode: substitute clutch control). If there is also a failure at output speed,

0004-23

03/15/2011 Rel(1.8) root(tsindxwp) wpno(T00009)

TM 10-3930-675-23-1

0004

EXPLANATION OF ERROR CODE DISPLAY - Continued Table 4. ERROR DISPLAY CODE LAYOUT Error Code Reference Index - Continued. ERROR CODE CATEGORY/ EXPLANATION defective. Incorrect sensor gap size. VEHICLE LIMITATIONS transmission ECU shifts to neutral. Limp home. Gearshift quality is reduced, due to another control mode (operating mode: substitute clutch control). If there is also a failure at output speed, transmission ECU shifts to neutral. Limp home. Gearshift quality is reduced, due to another control mode (operating mode: substitute clutch control). If there is also a failure at output speed, transmission ECU shifts to neutral. Limp home. Gearshift quality is reduced, due to another control mode (operating mode: substitute clutch control).

TROUBLESHOOTING PROCEDURE WORK PACKAGE

653

(WP 0026)

Warning - Degraded Operation Short circuit to ground at turbine speed input - transmission ECU measures a voltage less than 0.45V at speed input pin. Cables defective. Sensor defective.

654

(WP 0026)

Warning - Degraded Operation Logical error at turbine speed input - transmission ECU measures turbine speed over a threshold and at the next moment the measured speed is zero. Cables defective. Sensor defective. Incorrect sensor gap size.

655

(WP 0026)

Information/Maintenance Short circuit to battery voltage or open circuit at internal speed input - transmission ECU measures a voltage higher than 7.0V at speed input pin. Cables defective. Sensor defective. Information/Maintenance Short circuit to ground at internal speed input - transmission ECU measures a voltage less than 0.45V at speed input pin. Cables defective. Sensor defective.

656

(WP 0026)

Gearshift quality is reduced, due to another control mode (operating mode: substitute clutch control).

0004-24

03/15/2011 Rel(1.8) root(tsindxwp) wpno(T00009)

TM 10-3930-675-23-1

0004

EXPLANATION OF ERROR CODE DISPLAY - Continued Table 4. ERROR DISPLAY CODE LAYOUT 657 Error Code Reference Index - Continued. ERROR CODE CATEGORY/ EXPLANATION Information/Maintenance Logical error at internal speed input - transmission ECU measures internal speed over a threshold and at the next moment the measured speed is zero. Cables defective. Sensor defective. Incorrect sensor gap size. VEHICLE LIMITATIONS Gearshift quality is reduced, due to another control mode (operating mode: substitute clutch control). If there is also a failure at output speed, transmission ECU shifts to neutral. Limp home. Gearshift quality is reduced, due to another control mode (operating mode: substitute clutch control). If there is also a failure at turbine speed, transmission ECU shifts to neutral. Limp home. Gearshift quality is reduced, due to another control mode (operating mode: substitute clutch control). If there is also a failure at turbine speed, transmission ECU shifts to neutral. Limp home. Gearshift quality is reduced, due to another control mode (operating mode: substitute clutch control). If

TROUBLESHOOTING PROCEDURE WORK PACKAGE (WP 0026)

658

(WP 0026)

Warning - Degraded Operation Short circuit to battery voltage or open circuit at output speed input transmission ECU measures a voltage higher than 12.5V at speed input pin. Cables defective. Sensor defective.

659

(WP 0026)

Warning - Degraded Operation Short circuit to battery voltage at output speed input - transmission ECU measures a voltage less than 1.0V at speed input pin. Cables defective. Sensor defective.

660

(WP 0026)

Warning - Degraded Operation Logical error at output speed input - transmission ECU measures internal speed over a threshold and at the next moment the measured

0004-25

03/15/2011 Rel(1.8) root(tsindxwp) wpno(T00009)

TM 10-3930-675-23-1

0004

EXPLANATION OF ERROR CODE DISPLAY - Continued Table 4. ERROR DISPLAY CODE LAYOUT Error Code Reference Index - Continued. ERROR CODE CATEGORY/ EXPLANATION speed is zero. Cables defective. Sensor defective. VEHICLE LIMITATIONS there is also a failure at turbine speed, transmission ECU shifts to neutral. Limp home. Gearshift quality is reduced, due to another control mode (operating mode: substitute clutch control). If there is also a failure at turbine speed, transmission ECU shifts to neutral. Limp home. Error codes from transmission ECU will not show. Error codes from transmission ECU will not show. Transmission ECU shifts to neutral. Limp home. If there is also a failure at another clutch, ECU shifts to neutral. ECU will shut down. Reduced power and engine speed.

TROUBLESHOOTING PROCEDURE WORK PACKAGE

662

(WP 0026)

Warning - Degraded Operation Output speed does not fit other speed signals. If transmission is not in neutral and shifting has finished, transmission ECU measures output speed as zero and turbine or internal speed as not equal to zero. Cables defective. Sensor defective. Incorrect sensor gap size.

684

(WP 0013)

Warning - Degraded Operation CAN message time-out from display computer. Cable defective. Defective display computer. Warning - Degraded Operation CAN message time-out from display computer. Cable defective. Defective steering computer. Stop Vehicle Immediately Short circuit to battery voltage at clutch K1 - measured valve resistance is beyond limit, voltage at K1 valve is too high. Cables defective. Regulator defective.

685

(WP 0013)

713

(WP 0027)

0004-26

03/15/2011 Rel(1.8) root(tsindxwp) wpno(T00009)

TM 10-3930-675-23-1

0004

EXPLANATION OF ERROR CODE DISPLAY - Continued Table 4. ERROR DISPLAY CODE LAYOUT 714 Error Code Reference Index - Continued. ERROR CODE CATEGORY/ EXPLANATION Stop Vehicle Immediately Short circuit to ground at clutch K1 - measured valve resistance is beyond limit, voltage at K1 valve is too low. Cables defective. Regulator defective. VEHICLE LIMITATIONS Transmission ECU shifts to neutral. Limp home. If there is also a failure at another clutch, ECU shifts to neutral. ECU will shut down. Reduced power and engine speed. Transmission ECU shifts to neutral. Limp home. If there is also a failure at another clutch, ECU shifts to neutral. ECU will shut down. Reduced power and engine speed. Transmission ECU shifts to neutral. Limp home. If there is also a failure at another clutch, ECU shifts to neutral. ECU will shut down. Reduced power and engine speed. Transmission ECU shifts to neutral. Limp home. If there is also a failure at another clutch, ECU shifts to neutral. ECU will shut down.

TROUBLESHOOTING PROCEDURE WORK PACKAGE (WP 0027)

715

(WP 0027)

Stop Vehicle Immediately Open circuit at clutch K1 measured valve resistance is beyond limit. Cables defective. Regulator defective.

716

(WP 0027)

Stop Vehicle Immediately Short circuit to battery voltage at clutch K2 - measured valve resistance is beyond limit, voltage at K2 valve is too high. Cables defective. Regulator defective.

717

(WP 0027)

Stop Vehicle Immediately Short circuit to ground at clutch K2 - measured valve resistance is beyond limit, voltage at K2 valve is

0004-27

03/15/2011 Rel(1.8) root(tsindxwp) wpno(T00009)

TM 10-3930-675-23-1

0004

EXPLANATION OF ERROR CODE DISPLAY - Continued Table 4. ERROR DISPLAY CODE LAYOUT Error Code Reference Index - Continued. ERROR CODE CATEGORY/ EXPLANATION too low. Cables defective. Regulator defective. VEHICLE LIMITATIONS Reduced power and engine speed. Transmission ECU shifts to neutral. Limp home. If there is also a failure at another clutch, ECU shifts to neutral. ECU will shut down. Reduced power and engine speed. Transmission ECU shifts to neutral. Limp home. If there is also a failure at another clutch, ECU shifts to neutral. ECU will shut down. Reduced power and engine speed. Transmission ECU shifts to neutral. Limp home. If there is also a failure at another clutch, ECU shifts to neutral. ECU will shut down. Reduced power and engine speed. Transmission ECU shifts to neutral. Limp home. If there is also a failure at

TROUBLESHOOTING PROCEDURE WORK PACKAGE

718

(WP 0027)

Stop Vehicle Immediately Open circuit at clutch K2 measured valve resistance is beyond limit. Cables defective. Regulator defective.

719

(WP 0027)

Stop Vehicle Immediately Short circuit to battery voltage at clutch K3 - measured valve resistance is beyond limit, voltage at K3 valve is too high. Cables defective. Regulator defective.

720

(WP 0027)

Stop Vehicle Immediately Short circuit to ground at clutch K3 - measured valve resistance is beyond limit, voltage at K3 valve is too low. Cables defective. Regulator defective.

721

(WP 0027)

Stop Vehicle Immediately Open circuit at clutch K3 measured valve resistance is

0004-28

03/15/2011 Rel(1.8) root(tsindxwp) wpno(T00009)

TM 10-3930-675-23-1

0004

EXPLANATION OF ERROR CODE DISPLAY - Continued Table 4. ERROR DISPLAY CODE LAYOUT Error Code Reference Index - Continued. ERROR CODE CATEGORY/ EXPLANATION beyond limit. Cables defective. Regulator defective. VEHICLE LIMITATIONS another clutch, ECU shifts to neutral. ECU will shut down. Reduced power and engine speed. Transmission ECU shifts to neutral. Limp home. If there is also a failure at another clutch, ECU shifts to neutral. ECU will shut down. Reduced power and engine speed. Transmission ECU shifts to neutral. Limp home. If there is also a failure at another clutch, ECU shifts to neutral. ECU will shut down. Reduced power and engine speed. Transmission ECU shifts to neutral. Limp home. If there is also a failure at another clutch, ECU shifts to neutral. ECU will shut down. Reduced power and engine speed.

TROUBLESHOOTING PROCEDURE WORK PACKAGE

729

(WP 0027)

Stop Vehicle Immediately Short circuit to battery voltage at clutch K4 - measured valve resistance is beyond limit, voltage at K4 valve is too high. Cables defective. Regulator defective.

730

(WP 0027)

Stop Vehicle Immediately Short circuit to ground at clutch K4 - measured valve resistance is beyond limit, voltage at K4 valve is too low. Cables defective. Regulator defective.

731

(WP 0027)

Stop Vehicle Immediately Open circuit at clutch K4 measured valve resistance is beyond limit. Cables defective. Regulator defective.

0004-29

03/15/2011 Rel(1.8) root(tsindxwp) wpno(T00009)

TM 10-3930-675-23-1

0004

EXPLANATION OF ERROR CODE DISPLAY - Continued Table 4. ERROR DISPLAY CODE LAYOUT 732 Error Code Reference Index - Continued. ERROR CODE CATEGORY/ EXPLANATION Stop Vehicle Immediately Short circuit to battery voltage at clutch KV - measured valve resistance is beyond limit, voltage at KV valve is too high. Cables defective. Regulator defective. VEHICLE LIMITATIONS Transmission ECU shifts to neutral. Limp home. If there is also a failure at another clutch, ECU shifts to neutral. ECU will shut down. Reduced power and engine speed. Transmission ECU shifts to neutral. Limp home. If there is also a failure at another clutch, ECU shifts to neutral. ECU will shut down. Reduced power and engine speed. Transmission ECU shifts to neutral. Limp home. If there is also a failure at another clutch, ECU shifts to neutral. ECU will shut down. Reduced power and engine speed. Transmission ECU shifts to neutral. Limp home. If there is also a failure at another clutch, ECU shifts to neutral. ECU will shut down.

TROUBLESHOOTING PROCEDURE WORK PACKAGE (WP 0027)

733

(WP 0027)

Stop Vehicle Immediately Short circuit to ground at clutch KV - measured valve resistance is beyond limit, voltage at KV valve is too low. Cables defective. Regulator defective.

734

(WP 0027)

Stop Vehicle Immediately Open circuit at clutch KV measured valve resistance is beyond limit. Cables defective. Regulator defective.

735

(WP 0027)

Stop Vehicle Immediately Short circuit to battery voltage at clutch KR - measured valve resistance is beyond limit, voltage

0004-30

03/15/2011 Rel(1.8) root(tsindxwp) wpno(T00009)

TM 10-3930-675-23-1

0004

EXPLANATION OF ERROR CODE DISPLAY - Continued Table 4. ERROR DISPLAY CODE LAYOUT Error Code Reference Index - Continued. ERROR CODE CATEGORY/ EXPLANATION at KR valve is too high. Cables defective. Regulator defective. VEHICLE LIMITATIONS Reduced power and engine speed. Transmission ECU shifts to neutral. Limp home. If there is also a failure at another clutch, ECU shifts to neutral. ECU will shut down. Reduced power and engine speed. Transmission ECU shifts to neutral. Limp home. If there is also a failure at another clutch, ECU shifts to neutral. ECU will shut down. Reduced power and engine speed.

TROUBLESHOOTING PROCEDURE WORK PACKAGE

736

(WP 0027)

Stop Vehicle Immediately Short circuit to ground at clutch KR - measured valve resistance is beyond limit, voltage at KR valve is too low. Cables defective. Regulator defective.

737

(WP 0027)

Stop Vehicle Immediately Open circuit at clutch KR measured valve resistance is beyond limit. Cables defective. Regulator defective.

745

(WP 0028)

Information/Maintenance None. Short circuit to ground at reverse warning alarm relay - transmission ECU detected incorrect voltage at output pin that looks like a short circuit to battery voltage. Cables defective. Backup alarm device defective. Information/Maintenance None. Short circuit to battery voltage at reverse warning alarm relay transmission ECU detected incorrect voltage at output pin that looks like a short circuit to battery voltage. Cables defective. Backup alarm device defective.

746

(WP 0028)

0004-31

03/15/2011 Rel(1.8) root(tsindxwp) wpno(T00009)

TM 10-3930-675-23-1

0004

EXPLANATION OF ERROR CODE DISPLAY - Continued Table 4. ERROR DISPLAY CODE LAYOUT 747 Error Code Reference Index - Continued. ERROR CODE CATEGORY/ EXPLANATION Information/Maintenance Open circuit at reverse warning alarm relay - transmission ECU detected incorrect voltage at output pin that looks like an open circuit for this output pin. Cables defective. Backup alarm device defective. VEHICLE LIMITATIONS None.

TROUBLESHOOTING PROCEDURE WORK PACKAGE (WP 0028)

761

(WP 0028)

Warning - Degraded Operation Switching from Short circuit to ground at axle 2WD to 4WD is connection solenoid - transmission not possible. ECU detected incorrect voltage at output pin that looks like a short circuit to vehicle ground. Cables defective. Axle connection solenoid defective. Warning - Degraded Operation Switching from Short circuit to battery voltage axle 2WD to 4WD is connection solenoid - transmission not possible. ECU detected incorrect voltage at output pin that looks like a short circuit to battery voltage. Cables defective. Axle connection solenoid defective. Warning - Degraded Operation Open circuit at axle connection solenoid - transmission ECU detected incorrect voltage at output pin that looks like an open circuit for this output pin. Cables defective. Axle connection solenoid defective. Stop Vehicle Immediately Slippage at clutch K1 transmission ECU calculates a differential speed at closed clutch K1. If this calculated value is outside range, ECU interprets this as a slipping clutch. Low pressure. Switching from 2WD to 4WD is not possible.

762

(WP 0028)

763

(WP 0028)

777

(WP 0029)

Transmission ECU shifts to neutral. Limp home. If there is also a failure at another clutch, ECU shifts to neutral. ECU will shut down. Reduced power

0004-32

03/15/2011 Rel(1.8) root(tsindxwp) wpno(T00009)

TM 10-3930-675-23-1

0004

EXPLANATION OF ERROR CODE DISPLAY - Continued Table 4. ERROR DISPLAY CODE LAYOUT Error Code Reference Index - Continued. ERROR CODE CATEGORY/ EXPLANATION VEHICLE LIMITATIONS

TROUBLESHOOTING PROCEDURE WORK PACKAGE

Sensor defective. Incorrect sensor and engine gap size. Clutch defective. speed. 778 (WP 0029) Stop Vehicle Immediately Slippage at clutch K2 transmission ECU calculates a differential speed at closed clutch K2. If this calculated value is outside range, ECU interprets this as a slipping clutch. Low pressure. Sensor defective. Incorrect sensor gap size. Clutch defective. Transmission ECU shifts to neutral. Limp home. If there is also a failure at another clutch, ECU shifts to neutral. ECU will shut down. Reduced power and engine speed. ECU shifts to neutral. Limp home. If there is also a failure at another clutch, ECU shifts to neutral. ECU will shut down. Reduced power and engine speed. Transmission ECU shifts to neutral. Limp home. If there is also a failure at another clutch, ECU shifts to neutral. ECU will shut down. Reduced power and engine speed. Transmission ECU shifts to neutral. Limp home. If there is also a failure at another clutch, ECU shifts to

779

(WP 0029)

Stop Vehicle Immediately Slippage at clutch K3 transmission ECU calculates a differential speed at closed clutch K3. If this calculated value is outside range, ECU interprets this as a slipping clutch. Low pressure. Sensor defective. Incorrect sensor gap size. Clutch defective.

780

(WP 0029)

Stop Vehicle Immediately Slippage at clutch K4 transmission ECU calculates a differential speed at closed clutch K4. If this calculated value is outside range, ECU interprets this as a slipping clutch. Low pressure. Sensor defective. Incorrect sensor gap size. Clutch defective.

781

(WP 0029)

Stop Vehicle Immediately Slippage at clutch KV transmission ECU calculates a differential speed at closed clutch KV. If this calculated value is outside range, ECU interprets this as a slipping clutch. Low pressure.

0004-33

03/15/2011 Rel(1.8) root(tsindxwp) wpno(T00009)

TM 10-3930-675-23-1

0004

EXPLANATION OF ERROR CODE DISPLAY - Continued Table 4. ERROR DISPLAY CODE LAYOUT Error Code Reference Index - Continued. ERROR CODE CATEGORY/ EXPLANATION VEHICLE LIMITATIONS

TROUBLESHOOTING PROCEDURE WORK PACKAGE

Sensor defective. Incorrect sensor neutral. ECU will gap size. Clutch defective. shut down. Reduced power and engine speed. 782 (WP 0029) Stop Vehicle Immediately Slippage at clutch KR transmission ECU calculates a differential speed at closed clutch KR. If this calculated value is outside of range, ECU interprets this as a slipping clutch. Low pressure. Sensor defective. Incorrect sensor gap size. Clutch defective. Transmission ECU shifts to neutral. Limp home. If there is also a failure at another clutch, ECU shifts to neutral. ECU will shut down. Reduced power and engine speed.

783

(WP 0025)

Warning - Degraded Operation None. Overheated sump - transmission ECU measured temperature in oil sump that is over 212F (100C). Low oil level. Temperature sensor defective. Information/Maintenance None. Oil filter differential pressure transmission ECU measured a voltage at differential pressure switch outside allowable range. Oil filter polluted. Cable/connector defective. Differential switch defective. Warning - Degraded Operation None. Overheated converter output ECU measured oil temperature at converter output that is over 248F (120C). Low oil level. Temperature sensor defective. Stop Vehicle Immediately Low power at battery - measured voltage at power supply is lower Transmission ECU shifts to neutral. ECU will shut down. Reduced power

786

(WP 0038)

795

(WP 0025)

811

(WP 0015)

0004-34

03/15/2011 Rel(1.8) root(tsindxwp) wpno(T00009)

TM 10-3930-675-23-1

0004

EXPLANATION OF ERROR CODE DISPLAY - Continued Table 4. ERROR DISPLAY CODE LAYOUT Error Code Reference Index - Continued. ERROR CODE CATEGORY/ EXPLANATION VEHICLE LIMITATIONS

TROUBLESHOOTING PROCEDURE WORK PACKAGE

than 18V. Cable defective. Battery and engine defective. Connector defective. speed. 812 (WP 0015) Stop Vehicle Immediately High power at battery - measured voltage at power supply is higher than 32.5V. Cable defective. Battery defective. Connector defective. Transmission ECU shifts to neutral. ECU will shut down. Reduced power and engine speed. ECU shifts to neutral. ECU will shut down. Reduced power and engine speed. ECU shifts to neutral. ECU will shut down. Reduced power and engine speed. None.

813

(WP 0015)

Stop Vehicle Immediately Error at shift valve power supply (VPS1). Cable defective. Connector defective. ECU defective.

814

(WP 0015)

Stop Vehicle Immediately Error at shift valve power supply (VPS2). Cable defective. Connector defective. ECU defective.

841

(WP 0014)

Information/Maintenance General EEPROM fault - ECU cannot read memory. ECU defective. Stop Vehicle Immediately Application error. ECU defective.

843

(WP 0014)

Transmission stays in neutral. ECU will shut down. Reduced power and engine speed. Transmission stays in neutral. ECU will shut down. Reduced power and engine speed.

845

(WP 0029)

Stop Vehicle Immediately Clutch failure - AEB was not able to adjust clutch filling parameters. Clutch defective.

846

(WP 0029)

Information/Maintenance None. Clutch adjustment data lost - ECU was not able to read correct adjustment parameters.

0004-35

03/15/2011 Rel(1.8) root(tsindxwp) wpno(T00009)

TM 10-3930-675-23-1

0004

EXPLANATION OF ERROR CODE DISPLAY - Continued Table 4. ERROR DISPLAY CODE LAYOUT Error Code Reference Index - Continued. ERROR CODE CATEGORY/ EXPLANATION Interference during data saving process. 1111 (WP 0014) Stop Vehicle Immediately ECM internal memory error. Hardware defective. Internal microprocessor communication failure. Stop Vehicle Immediately No engine speed signal detected in either engine position sensor circuits. Engine will not start. Reduced power and engine speed. VEHICLE LIMITATIONS

TROUBLESHOOTING PROCEDURE WORK PACKAGE

1115

(WP 0018)

Engine will shut down and will not start. Reduced power and engine speed.

1121

(WP 0018)

Warning - Degraded Operation None. No engine speed signal detected in one engine position sensor circuit. Warning - Degraded Operation High voltage detected in intake manifold pressure sensor circuit. Warning - Degraded Operation Low voltage detected in intake manifold pressure sensor circuit. Stop Vehicle Immediately High voltage detected in throttle position sensor circuit. Reduced engine power output.

1122

(WP 0022)

1123

(WP 0022)

Reduced engine power output.

1131

(WP 0008)

Severe power and speed loss. Limp home power only. Reduced power and engine speed. Severe power and speed loss. Limp home power only. Reduced power and engine speed. Oil pressure warning not working.

1132

(WP 0008)

Stop Vehicle Immediately Low voltage detected in throttle position sensor circuit.

1135

(WP 0019)

Warning - Degraded Operation High voltage detected in oil pressure sensor circuit.

0004-36

03/15/2011 Rel(1.8) root(tsindxwp) wpno(T00009)

TM 10-3930-675-23-1

0004

EXPLANATION OF ERROR CODE DISPLAY - Continued Table 4. ERROR DISPLAY CODE LAYOUT 1141 Error Code Reference Index - Continued. ERROR CODE CATEGORY/ EXPLANATION Warning - Degraded Operation Low voltage detected in oil pressure sensor circuit. VEHICLE LIMITATIONS Oil pressure warning not working.

TROUBLESHOOTING PROCEDURE WORK PACKAGE (WP 0019)

1143

(WP 0019)

Stop Vehicle Immediately Reduced power Oil pressure signal indicates low oil and speed. pressure. Engine will shut down in 30 to 45 seconds. Warning - Degraded Operation High voltage detected in coolant temperature circuit. Warning - Degraded Operation Low voltage detected in coolant temperature circuit. Stop Vehicle Immediately Coolant temperature signal indicated coolant temperature above critical threshold. Temperature warning not functioning. Temperature warning not functioning. Reduced power and speed. Engine will shut down in 30 to 45 seconds. Possible white smoke. No engine protection for intake manifold temperature. Possible white smoke. No engine protection for intake manifold temperature. Reduced power and speed. Engine will shut down in 30 to 45 seconds.

1144

(WP 0020)

1145

(WP 0020)

1151

(WP 0020)

1153

(WP 0020)

Warning - Degraded Operation High voltage detected in intake manifold temperature sensor circuit.

1154

(WP 0020)

Warning - Degraded Operation Low voltage detected in intake manifold temperature sensor circuit.

1155

(WP 0020)

Stop Vehicle Immediately Intake manifold temperature signal indicated coolant temperature above critical threshold.

0004-37

03/15/2011 Rel(1.8) root(tsindxwp) wpno(T00009)

TM 10-3930-675-23-1

0004

EXPLANATION OF ERROR CODE DISPLAY - Continued Table 4. ERROR DISPLAY CODE LAYOUT 1187 Error Code Reference Index - Continued. ERROR CODE CATEGORY/ EXPLANATION Warning - Degraded Operation Low voltage detected on ECM voltage supply line to some sensors. Warning - Degraded Operation High voltage detected in oil temperature sensor circuit. Warning - Degraded Operation Low voltage detected in oil temperature sensor circuit. Stop Vehicle Immediately Oil pressure signal indicates temperature above critical threshold. Information/Maintenance High voltage detected in ambient air pressure sensor circuit. Information/Maintenance Low voltage detected in ambient air pressure sensor circuit. Warning - Degraded Operation High voltage detected on ECM voltage supply line to some sensors. Stop Vehicle Immediately Engine speed signal indicates engine speed greater than 2,730 RPM. VEHICLE LIMITATIONS Engine will run degraded. No protection for oil pressure. No engine protection for oil temperature. No engine protection for oil temperature. Reduced power and speed.

TROUBLESHOOTING PROCEDURE WORK PACKAGE (WP 0017)

1212

(WP 0020)

1213

(WP 0020)

1214

(WP 0020)

1221

(WP 0021)

Reduced power and speed.

1222

(WP 0021)

Reduced power and speed.

1227

(WP 0017)

Engine will run degraded. No protection for oil pressure. Fuel shutoff valve is closed until engine speed drops. Fuel shutoff valve will open when engine speed falls below 2,184 RPM. Reduced power and engine speed. ECM turns off FSO supply voltage. Engine will shut down.

1234

(WP 0018)

1254

(WP 0023)

Stop Vehicle Immediately

0004-38

03/15/2011 Rel(1.8) root(tsindxwp) wpno(T00009)

TM 10-3930-675-23-1

0004

EXPLANATION OF ERROR CODE DISPLAY - Continued Table 4. ERROR DISPLAY CODE LAYOUT Error Code Reference Index - Continued. ERROR CODE CATEGORY/ EXPLANATION Less than 6V detected at fuel shutoff driver. Excessive current draw. Power supply faulty. 1255 (WP 0023) Warning - Degraded Operation Externally supplied voltage detected going to fuel shutoff supply circuit. Warning - Degraded Operation Information from multiplexed device not received by ECM or received too late. Warning - Degraded Operation Only a portion of information from multiplexed device received by ECM. VEHICLE LIMITATIONS Reduced power and engine speed. No performance limitations. Fuel shutoff valve stays open. At least one multiplexed device will not operate properly. At least one multiplexed device will not operate properly.

TROUBLESHOOTING PROCEDURE WORK PACKAGE

1285

(WP 0013)

1286

(WP 0013)

1287

(WP 0017)

Stop Vehicle Immediately The engine will Data error received while only idle. multiplexing throttle pedal and IVS. Reduced power and engine speed. Information/Maintenance Engine is Ambient air pressure sensor circuit degraded to no error detected by ECM. air setting. Stop Vehicle Immediately Reduced power Intake system indicates air cleaner and speed. is clogged. Information/Maintenance Injector for Current detected at injector for cylinder #1 cylinder #1 when voltage is turned turned OFF. OFF. Information/Maintenance Injector for Current detected at injector for cylinder #5 cylinder #5 when voltage is turned turned OFF. OFF. Information/Maintenance Injector for Current detected at injector for cylinder #3 cylinder #3 when voltage is turned turned OFF. OFF.

1295

(WP 0021)

1298

(WP 0021)

1311

(WP 0007)

1312

(WP 0007)

1313

(WP 0007)

0004-39

03/15/2011 Rel(1.8) root(tsindxwp) wpno(T00009)

TM 10-3930-675-23-1

0004

EXPLANATION OF ERROR CODE DISPLAY - Continued Table 4. ERROR DISPLAY CODE LAYOUT 1314 Error Code Reference Index - Continued. ERROR CODE CATEGORY/ EXPLANATION VEHICLE LIMITATIONS

TROUBLESHOOTING PROCEDURE WORK PACKAGE (WP 0007)

Information/Maintenance Injector for Current detected at injector for cylinder #6 cylinder #6 when voltage is turned turned OFF. OFF. Information/Maintenance Injector for Current detected at injector for cylinder #2 cylinder #2 when voltage is turned turned OFF. OFF. Information/Maintenance Injector for Current detected at injector for cylinder #4 cylinder #4 when voltage is turned turned OFF. OFF. Information/Maintenance Injector for No current detected at injector for cylinder #1 cylinder #1 when voltage is turned turned OFF. OFF. Information/Maintenance Injector for No current detected at injector for cylinder #5 cylinder #5 when voltage is turned turned ON. ON. Information/Maintenance Injector for Current detected at injector for cylinder #3 cylinder #3 when voltage is turned turned ON. ON. Information/Maintenance Injector for Current detected at injector for cylinder #6 cylinder #6 when voltage is turned turned ON. ON. Information/Maintenance Injector for No current detected at injector for cylinder #2 cylinder #2 when voltage is turned turned ON. ON. Information/Maintenance Injector for No current detected at injector for cylinder #4 cylinder #4 when voltage is turned turned OFF. ON.

1315

(WP 0007)

1321

(WP 0007)

1322

(WP 0007)

1323

(WP 0007)

1324

(WP 0007)

1325

(WP 0007)

1331

(WP 0007)

1332

(WP 0007)

0004-40

03/15/2011 Rel(1.8) root(tsindxwp) wpno(T00009)

TM 10-3930-675-23-1

0004

EXPLANATION OF ERROR CODE DISPLAY - Continued Table 4. ERROR DISPLAY CODE LAYOUT 1341 Error Code Reference Index - Continued. ERROR CODE CATEGORY/ EXPLANATION Warning - Degraded Operation Severe loss of data from ECM. VEHICLE LIMITATIONS No noticeable performance effects possible. Possibility of engine stopping or difficulty in starting engine. No noticeable performance effects possible. May encounter severe loss of power. Possibly too short of time for ECM to power down, less than 30 seconds. Engine is degraded to no air setting.

TROUBLESHOOTING PROCEDURE WORK PACKAGE (WP 0014)

1343

(WP 0014)

Warning - Degraded Operation Microprocessor communication error inside ECM.

1346

(WP 0014)

Information/Maintenance Software error in ECM.

1352

(WP 0017)

Warning - Degraded Operation Low voltage detected at sensor. Faulty power supply.

1415

(WP 0019)

Stop Vehicle Immediately Reduced power Oil pressure signal indicates below and speed. critical threshold. Engine will shut down in 30 to 45 seconds. Information/Maintenance Error in intake manifold pressure sensor signal detected by ECM. Engine is degraded to no air setting.

1419

(WP 0022)

1431

(WP 0008)

Information/Maintenance None. Both idle validation off-idle and onidle signals indicate the same voltage reading. Warning - Degraded Operation Idle validation switch voltages are opposite (complementary) but disagree with a valid throttle position sensor. Engine will only idle.

1432

(WP 0008)

0004-41

03/15/2011 Rel(1.8) root(tsindxwp) wpno(T00009)

TM 10-3930-675-23-1

0004

EXPLANATION OF ERROR CODE DISPLAY - Continued Table 4. ERROR DISPLAY CODE LAYOUT 1433 Error Code Reference Index - Continued. ERROR CODE CATEGORY/ EXPLANATION Information/Maintenance Intake manifold pressure sensor voltage indicates a high pressure reading. Warning - Degraded Operation Battery voltage too low or insufficient amount of time for battery power to ECM for powering down after key off. VEHICLE LIMITATIONS Engine is degraded to no air setting.

TROUBLESHOOTING PROCEDURE WORK PACKAGE (WP 0022)

1434

(WP 0024)

No noticeable performance effects possible. Possibility of engine stopping or difficulty in starting engine. None. No engine protection for oil pressure. No noticeable performance effects possible. Possibility of rough idle. None.

1435

(WP 0019)

Warning - Degraded Operation ECM detects error in oil pressure sensor signal. Warning - Degraded Operation Battery voltage below normal operating level.

1441

(WP 0024)

1442

(WP 0024)

Warning - Degraded Operation Battery voltage above normal operating level. Warning - Degraded Operation Low voltage detected on ECM voltage supply line to throttle. Warning - Degraded Operation Low voltage detected in starter lockout relay circuit when energized or voltage detected when circuit de-energized. Warning - Degraded Operation No voltage detected simultaneously in both idle validation off-idle and on-idle circuits. Warning - Degraded Operation High voltage detected in fuel inlet pressure sensor circuit.

1443

(WP 0017)

Engine will only idle.

1474

(WP 0024)

None.

1551

(WP 0008)

Engine will only idle.

1581

(WP 0023)

None.

0004-42

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TM 10-3930-675-23-1

0004

EXPLANATION OF ERROR CODE DISPLAY - Continued Table 4. ERROR DISPLAY CODE LAYOUT 1596 Error Code Reference Index - Continued. ERROR CODE CATEGORY/ EXPLANATION Warning - Degraded Operation Battery voltage above normal operating range. Warning - Degraded Operation Battery voltage below normal operating range. Stop Vehicle Immediately Very low battery voltage - critical level. VEHICLE LIMITATIONS None.

TROUBLESHOOTING PROCEDURE WORK PACKAGE (WP 0024)

1597

(WP 0024)

None.

1598

(WP 0024)

Engine is degraded to no air setting.

1697

(WP 0020)

Information/Maintenance None. High voltage detected in ECM internal temperature sensor circuit. Information/Maintenance None. Low voltage detected in ECM internal temperature sensor circuit. Information/Maintenance Power imbalance between cylinders detected by ECM. Engine may rough idle or misfire.

1698

(WP 0020)

1951

(WP 0007)

1999

Stop Vehicle Immediately Engine is More than 6 errors active on J1939 degraded to no bus to display. air setting.

END OF WORK PACKAGE

0004-43/44 blank

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0005

FIELD MAINTENANCE TROUBLESHOOTING SYMPTOM INDEX

ERROR CODE SYMPTOM INDEX Malfunction/Symptom Troubleshooting Procedure

AUXILIARY PUMP 1. 2. 3. Error Code 169 - Tophandler Emergency Function Supply Valve, Open or Short Circuit Failure ................................................................................................. WP 0036 Error Code 411 - Auxiliary Pump Control, Short Circuit Failure ....................................................... WP 0036 Error Code 417 - Auxiliary Pump Switch, Circuit Input Error ............................................................ WP 0036

AXLE BRAKE COOLING SYSTEM 1. 2. 3. Error Code 191 - Temperature in Front Axle Above Critical Threshold ......................................................................................................................................... WP 0031 Error Code 192 - Temperature in Rear Axle Above Critical Threshold ......................................................................................................................................... WP 0031 Error Code 414 - Brake Cooling Bypass Valve, Short Circuit Failure .............................................................................................................................................. WP 0031

BOOM IN/OUT 1. 2. 3. 4. 5. 6. Error Code 127 - Joystick-to-ECU (790) Failure .............................................................................. WP 0040 Error Code 130 - Overload Protection System Failure ..................................................................... WP 0040 Error Code 160 - Extension Cylinder Boom IN Control, Wiring Circuit Failure ................................................................................................................................... WP 0040 Error Code 161 - Extension Cylinder Boom IN Control, Component Failure ........................................................................................................................... WP 0040 Error Code 163 - Extension Cylinder Boom OUT Control Valve, Wiring Circuit Failure ........................................................................................................................ WP 0040 Error Code 164 - Extension Cylinder Boom OUT Control Valve, Component Failure ........................................................................................................................... WP 0040

BOOM LIFTING/LOWERING 1. 2. 3. 4. 5. Error Code 126 - Joystick-to-ECU (790) Failure .............................................................................. WP 0039 Error Code 130 - Overload Protection System Failure ..................................................................... WP 0039 Error Code 151 - Lift Cylinder Locking Valve, Wiring Circuit Failure .............................................................................................................................................. WP 0039 Error Code 152 - Lift Cylinder Locking Valve, Component Failure ................................................... WP 0039 Error Code 154 - Lift Cylinder Boom Up Valve, Wiring Circuit Failure .............................................................................................................................................. WP 0039

0005-1

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TM 10-3930-675-23-1

0005

ERROR CODE SYMPTOM INDEX - Continued Malfunction/Symptom Troubleshooting Procedure

6. 7. 8.

Error Code 155 - Lift Cylinder Boom Up Valve, Component Failure .............................................................................................................................................. WP 0039 Error Code 157 - Lift Cylinder Boom Down Valve, Wiring Circuit Failure .............................................................................................................................................. WP 0039 Error Code 158 - Lift Cylinder Boom Down Valve, Component Failure .............................................................................................................................................. WP 0039

BRAKE SYSTEM 1. 2. 3. Error Code 118 - Brake System Pressure, Circuit 1 and Circuit 2 Failure ........................................................................................................................................... WP 0030 Error Code 119 - Brake System Pressure, Circuit 1 Failure ............................................................. WP 0030 Error Code 120 - Brake System Pressure, Circuit 2 Failure ............................................................. WP 0030

COOLING FAN OPERATION AND FAN CONTROL 1. 2. 3. Error Code 166 - Cooling Fan Speed, Wiring Circuit Failure ........................................................... WP 0009 Error Code 167 - Cooling Fan Speed, Short Circuit Failure ............................................................. WP 0009 Error Code 426 - Fording Level Switch, Circuit Input Error .............................................................. WP 0009

ECU-TO-ECU COMMUNICATIONS 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. Error Code 103 - ECU (790) Not Responding (RT 240V1R, RT 240V2 and RT 240V3) ..................................................................................................................... WP 0013 Error Code 105 - ECU (790) Not Responding .................................................................................. WP 0013 Error Code 106 - ECU (791) Not Responding .................................................................................. WP 0013 Error Code 107 - Cable Failure Between Tophandler ECU (791) and Display ECU (795) .................................................................................................................... WP 0013 Error Code 108 - Cable Failure Between Tophandler ECU (791) and Servo ECU (790) ....................................................................................................................... WP 0013 Error Code 109 - Cable Failure Between Servo ECU (790) and Display ECU (795) ........................................................................................................................... WP 0013 Error Code 110 - Communication Failure Between Display ECU (795) and Steering ECU (792) ......................................................................................................... WP 0013 Error Code 111 - Communication Failure Between Display ECU (795) and Transmission ECU (793) .................................................................................................. WP 0013 Error Code 112 - Communication Failure Between Display ECU (795) and Engine ECU (794) ............................................................................................................ WP 0013 Error Code 345 - Communication Failure Between Steering ECU (792) and Display ECU (795) ................................................................................................... WP 0013

0005-2

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TM 10-3930-675-23-1

0005

ERROR CODE SYMPTOM INDEX - Continued Malfunction/Symptom 11. 12. 13. 14. 15. Troubleshooting Procedure

Error Code 346 - Communication Failure Between Steering ECU (792) and Transmission ECU (793) ......................................................................................... WP 0013 Error Code 684 - Communication Failure Between Transmission ECU (793) and Display ECU (795) ............................................................................ WP 0013 Error Code 685 - Communication Failure Between Transmission ECU (793) and Steering ECU (792) ........................................................................... WP 0013 Error Code 1285 - Engine Detects a Communication Failure on the J1939 Datalink ........................................................................................................................... WP 0013 Error Code 1286 - Engine Detects a Communication Failure on the J1939 Datalink ........................................................................................................................... WP 0013

ELECTRONIC CONTROL UNIT (ECU) SUPPLY VOLTAGE 1. 2. 3. 4. 5. 6. 7. 8. Error Code 451 - Voltage Supply Too High for Steering ECU (792) ................................................................................................................................................. WP 0015 Error Code 452 - Voltage Supply Too Low for Steering ECU (792) ................................................................................................................................................. WP 0015 Error Code 453 - Wheel Sensor Supply Voltage Out of Range (RT 240V1R, RT 240V2 and RT 240V3) .......................................................................................... WP 0015 Error Code 454 - Wheel Sensor Supply Voltage Out of Range (RT 240V1R, RT 240V2 and RT 240V3) .......................................................................................... WP 0015 Error Code 811 - Voltage Supply Too Low for Transmission ECU (793) ........................................................................................................................................ WP 0015 Error Code 812 - Voltage Supply Too High for Transmission ECU (793) ........................................................................................................................................ WP 0015 Error Code 813 - Voltage Failure at Transmission Gearshift Valve Supply .................................................................................................................................... WP 0015 Error Code 814 - Voltage Failure at Transmission Gearshift Valve Power Supply ......................................................................................................................... WP 0015

ELECTRONIC CONTROL UNIT (ECU) INPUT VOLTAGE 1. 2. 3. 4. 5. 6. Error Code 121 - Supply Voltage to Servo ECU (790) Failure ......................................................... WP 0012 Error Code 122 - Supply Voltage to Servo ECU (790) Failure ......................................................... WP 0012 Error Code 123 - 10V Reference Voltage for Servo ECU (790) Short Circuit Failure ......................................................................................................................... WP 0012 Error Code 201 - Supply Voltage to Tophandler ECU (791) Failure .............................................................................................................................................. WP 0012 Error Code 202 - Supply Voltage to Tophandler ECU (791) Failure .............................................................................................................................................. WP 0012 Error Code 203 - 10V Reference Voltage for Tophandler ECU (791) Failure ..................................................................................................................................... WP 0012

0005-3

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TM 10-3930-675-23-1

0005

ERROR CODE SYMPTOM INDEX - Continued Malfunction/Symptom Troubleshooting Procedure

ENGINE AMBIENT AIR PRESSURE SENSOR AND CIRCUITS 1. 2. 3. 4. Error Code 1221 - High Voltage Detected at Ambient Air Pressure Sensor Circuit ................................................................................................................... WP 0021 Error Code 1222 - Low Voltage Detected at Ambient Air Pressure Sensor Circuit ................................................................................................................... WP 0021 Error Code 1295 - Ambient Air Pressure Sensor Circuit Failure ...................................................... WP 0021 Error Code 1298 - High Intake Air Restriction or Circuit Failure (RT 240V1R, RT 240V2 and RT 240V3) .......................................................................................... WP 0021

ENGINE BATTERY VOLTAGE CIRCUITS 1. 2. 3. 4. 5. Error Code 1434 - Unswitched Battery Supply Circuit Failure ......................................................... WP 0024 Error Code 1441 - Unswitched Battery Supply Circuit Failure ......................................................... WP 0024 Error Code 1442 - Unswitched Battery Supply Circuit Failure. ........................................................ WP 0024 Error Code 1474 - Starter Solenoid Lockout Relay Driver Circuit Failure .............................................................................................................................................. WP 0024 Error Code 1596 - Voltage Monitor, High Voltage Failure ................................................................ WP 0024

ENGINE FUEL INJECTOR CIRCUITS 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. Error Code 1311 - Injector Circuit Failure ......................................................................................... WP 0007 Error Code 1312 - Injector Circuit Failure ......................................................................................... WP 0007 Error Code 1313 - Injector Circuit Failure ......................................................................................... WP 0007 Error Code 1314 - Injector Circuit Failure ......................................................................................... WP 0007 Error Code 1315 - Injector Circuit Failure ......................................................................................... WP 0007 Error Code 1321 - Injector Circuit Failure ......................................................................................... WP 0007 Error Code 1322 - Injector Circuit Failure ......................................................................................... WP 0007 Error Code 1323 - Injector Circuit Failure ......................................................................................... WP 0007 Error Code 1324 - Injector Circuit Failure ......................................................................................... WP 0007 Error Code 1325 - Injector Circuit Failure ......................................................................................... WP 0007 Error Code 1331 - Injector Circuit Failure ......................................................................................... WP 0007 Error Code 1332 - Injector Circuit Failure ......................................................................................... WP 0007 Error Code 1951 - Injector Circuit Failure ......................................................................................... WP 0007

ENGINE FUEL PRESSURE SENSORS AND CIRCUITS 1. Error Code 1254 - Fuel Shutoff Solenoid Circuit Failure .................................................................. WP 0023

0005-4

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TM 10-3930-675-23-1

0005

ERROR CODE SYMPTOM INDEX - Continued Malfunction/Symptom 2. 3. Troubleshooting Procedure

Error Code 1255 - Fuel Shutoff Solenoid External Voltage Detected on Circuit ........................................................................................................................... WP 0023 Error Code 1581 - Fuel Inlet Restriction Sensor Circuit Failure ....................................................... WP 0023

ENGINE ELECTRONIC CONTROL UNIT (ECU) (794) 1. 2. 3. 4. 5. Error Code 1187 - Sensor Voltage Supply Failure ........................................................................... WP 0017 Error Code 1227 - Sensor Voltage Supply Failure ........................................................................... WP 0017 Error Code 1287 - Sensor Voltage Supply Failure ........................................................................... WP 0017 Error Code 1352 - Sensor Voltage Supply Failure ........................................................................... WP 0017 Error Code 1443 - Low Voltage Detected at Throttle Position Sensor Circuit ................................................................................................................................... WP 0017

ENGINE OIL PRESSURE 1. 2. 3. 4. 5. Error Code 1135 - Oil Pressure Sensor Circuit Failure .................................................................... WP 0019 Error Code 1141 - Oil Pressure Sensor Circuit Failure .................................................................... WP 0019 Error Code 1143 - Oil Pressure Sensor Circuit Failure .................................................................... WP 0019 Error Code 1415 - Oil Pressure Sensor Circuit Failure .................................................................... WP 0019 Error Code 1435 - Oil Pressure Sensor Circuit Failure .................................................................... WP 0019

ENGINE POSITION SENSOR CIRCUITS 1. 2. 3. Error Code 1115 - Engine Position Sensor Circuit Failure ............................................................... WP 0018 Error Code 1121 - Engine Position Sensor Circuit Failure ............................................................... WP 0018 Error Code 1234 - Engine Overspeed Failure .................................................................................. WP 0018

ENGINE PRESSURE SENSOR 1. 2. 3. 4. Error Code 1122 - Intake Manifold Pressure Sensor Circuit Failure .............................................................................................................................................. WP 0022 Error Code 1123 - Intake Manifold Pressure Sensor Circuit Failure .............................................................................................................................................. WP 0022 Error Code 1419 - Intake Manifold Pressure Sensor Circuit Failure .............................................................................................................................................. WP 0022 Error Code 1433 - Intake Manifold Pressure Sensor Circuit Failure .............................................................................................................................................. WP 0022

ENGINE TEMPERATURE SENSORS AND CIRCUITS 1. Error Code 1144 - Coolant Temperature Sensor Circuit Failure ...................................................... WP 0020

0005-5

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TM 10-3930-675-23-1

0005

ERROR CODE SYMPTOM INDEX - Continued Malfunction/Symptom 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. Troubleshooting Procedure

Error Code 1145 - Coolant Temperature Sensor Circuit Failure ...................................................... WP 0020 Error Code 1151 - Coolant Temperature Above Critical Threshold ......................................................................................................................................... WP 0020 Error Code 1153 - Intake Air Temperature Sensor Circuit Failure ................................................... WP 0020 Error Code 1154 - Intake Air Temperature Sensor Circuit Failure ................................................... WP 0020 Error Code 1155 - Intake Air Temperature Above Critical Threshold ......................................................................................................................................... WP 0020 Error Code 1212 - Oil Temperature Sensor Circuit Failure .............................................................. WP 0020 Error Code 1213 - Oil Temperature Sensor Circuit Failure .............................................................. WP 0020 Error Code 1214 - Oil Temperature Above Critical Threshold ......................................................... WP 0020 Error Code 1697 - ECU Internal Temperature Sensor Circuit Failure .............................................................................................................................................. WP 0020 Error Code 1698 - ECU Internal Temperature Sensor Circuit Failure .............................................................................................................................................. WP 0020

ENGINE TPS AND IDLE VALIDATION SWITCH 1. 2. 3. 4. 5. Error Code 1131 - High Voltage Detected at Throttle Position Sensor Circuit ................................................................................................................................... WP 0008 Error Code 1132 - Low Voltage Detected at Throttle Position Sensor Circuit ................................................................................................................................... WP 0008 Error Code 1431 - High Voltage Detected at Both Idle Validation Signal Circuits .................................................................................................................................. WP 0008 Error Code 1432 - Wrong Voltage Signals Detected at Throttle Position Sensor and Idle Validation Circuits ..................................................................................... WP 0008 Error Code 1551 - No Voltage Detected at Both Idle Validation Signal Circuits .................................................................................................................................. WP 0008

HYDRAULIC FILTER INDICATORS 1. 2. 3. 4. 5. Error Code 1 - Boom Hydraulic System Sensor Indicating Clogged Filter ................................................................................................................................... WP 0038 Error Code 2 - Steering Hydraulic System Sensor Indicating Clogged Filter ................................................................................................................................... WP 0038 Error Code 3 - Tophandler Hydraulic System Sensor Indicating Clogged Filter ................................................................................................................................... WP 0038 Error Code 4 - Hydraulic Reservoir Return Sensor Indicating Clogged Filter ................................................................................................................................... WP 0038 Error Code 432 - Boom Hydraulic Filter Sensor, Circuit Error Input ................................................................................................................................................. WP 0038

0005-6

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TM 10-3930-675-23-1

0005

ERROR CODE SYMPTOM INDEX - Continued Malfunction/Symptom 6. 7. 8. 9. Troubleshooting Procedure

Error Code 433 - Steering Hydraulic Filter Sensor, Circuit Input Error ................................................................................................................................................. WP 0038 Error Code 434 - Tophandler Hydraulic Filter Sensor, Circuit Input Error ........................................................................................................................................ WP 0038 Error Code 435 - Hydraulic Reservoir Return System Filter Sensor, Circuit Input Error ................................................................................................................ WP 0038 Error Code 786 - Transmission Hydraulic System Sensor Indicating Clogged Filter .................................................................................................................. WP 0038

HYDRAULIC PISTON PUMP CUT-OFF 1. Error Code 172 - Hydraulic Piston Pump Cut-Off, Open or Short Circuit Failure ................................................................................................................................... WP 0037

HYDRAULIC SERVO SYSTEM ELECTRONIC CONTROL UNIT (ECU) (790) 1. 2. 3. Error Code 125 - Memory Failure ..................................................................................................... WP 0035 Error Code 141 - Internal Communication Failure ............................................................................ WP 0035 Error Code 142 - Internal Communication Failure ............................................................................ WP 0035

INPUT AND OUTPUT SIGNALS FOR STEERING 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. Error Code 350 - Right Front Wheel Valve Solenoid Error ............................................................... WP 0016 Error Code 351 - Right Rear Wheel Valve Solenoid Error ............................................................... WP 0016 Error Code 352 - Left Rear Wheel Valve Solenoid Error .................................................................. WP 0016 Error Code 353 - Left Front Wheel Valve Solenoid Error ................................................................. WP 0016 Error Code 354 - Right Front Wheel Valve Solenoid Error ............................................................... WP 0016 Error Code 355 - Right Rear Wheel Valve Solenoid Error ............................................................... WP 0016 Error Code 356 - Left Rear Wheel Valve Solenoid Error .................................................................. WP 0016 Error Code 357 - Right Front Wheel Valve Solenoid Error ............................................................... WP 0016 Error Code 399 - EEPROM Parameter Error in ECU (792) ............................................................. WP 0016 Error Code 401 - Transmission Neutral Signal from Steering ECU (792) Short Circuit Failure ........................................................................................................ WP 0016 Error Code 404 - 2WD Steering Control Lamp, Short Circuit Failure .............................................................................................................................................. WP 0016 Error Code 405 - 4WD Steering Control Lamp, Short Circuit Failure .............................................................................................................................................. WP 0016 Error Code 406 - Crab Steering Control Lamp, Short Circuit Failure .............................................................................................................................................. WP 0016

0005-7

03/15/2011 Rel(1.8) root(tsindxwp) wpno(T00010)

TM 10-3930-675-23-1

0005

ERROR CODE SYMPTOM INDEX - Continued Malfunction/Symptom 14. 15. 16. 17. 18. 19. 20. 21. 22. 23. 24. 25. 26. 27. 28. Troubleshooting Procedure

Error Code 408 - Unlocked Twistlock Control Lamp, Short Circuit Failure ................................................................................................................................... WP 0016 Error Code 409 - Locked Twistlock Control Lamp, Short Circuit Failure .............................................................................................................................................. WP 0016 Error Code 410 - Alignment Control Lamp, Short Circuit Failure ..................................................... WP 0016 Error Code 412 - Autolube Pump Control, Short Circuit Failure (RT 240V2 and RT 240V3) .............................................................................................................. WP 0016 Error Code 413 - Boom Folding Supply Valve, Short Circuit Failure .............................................................................................................................................. WP 0016 Error Code 415 - Drag Restriction, Short Circuit Failure (RT 240V1R, RT 240V2 and RT 240V3) ................................................................................................. WP 0016 Error Code 416 - Steering Pressure Switch, Circuit Input Error ....................................................... WP 0016 Error Code 418 - 2WD Steering Selection Switch, Circuit Input Error ................................................................................................................................................. WP 0016 Error Code 419 - 4WD Steering Selection Switch, Circuit Failure .................................................... WP 0016 Error Code 420 - Crab Steering Selection Switch, Circuit Failure .................................................... WP 0016 Error Code 422 - Cab in Transport Proximity Switch, Circuit Input Error ........................................................................................................................................ WP 0016 Error Code 423 - Ether Start Switch, Circuit Failure ......................................................................... WP 0016 Error Code 427 - Tophandler Work Light Switch, Circuit Input Error ................................................................................................................................................. WP 0016 Error Code 440 - Steering Wheel Sensor, Power Supply Error (RT 240V1R, RT 240V2 and RT 240V3) .......................................................................................... WP 0016 Error Code 450 - Temperature Inside Steering ECU (792) Above Critical Threshold [184F (85C)] .......................................................................................... WP 0016

INTERNAL TRANSMISSION CLUTCH SLIPPAGE FAILURE 1. 2. 3. 4. 5. 6. 7. 8. Error Code 777 - Internal Transmission Failure at Clutch K1 ........................................................... WP 0029 Error Code 778 - Internal Transmission Failure at Clutch K2 ........................................................... WP 0029 Error Code 779 - Internal Transmission Failure at Clutch K3 ........................................................... WP 0029 Error Code 780 - Internal Transmission Failure at Clutch K4 ........................................................... WP 0029 Error Code 781 - Internal Transmission Failure at Clutch KV .......................................................... WP 0029 Error Code 782 - Internal Transmission Failure at Clutch KR .......................................................... WP 0029 Error Code 845 - Clutch Failure Detected During Calibration .......................................................... WP 0029 Error Code 846 - Clutch Adjustment Data Lost ................................................................................ WP 0029

0005-8

03/15/2011 Rel(1.8) root(tsindxwp) wpno(T00010)

TM 10-3930-675-23-1

0005

ERROR CODE SYMPTOM INDEX - Continued Malfunction/Symptom Troubleshooting Procedure

MECHANICAL OR HYDRAULIC STEERING FAILURE 1. 2. 3. 4. 5. 6. 7. 8. Error Code 317 - Right-Front Wheel Angle Cannot Reach Set Point Value ....................................................................................................................................... WP 0033 Error Code 318 - Right-Rear Wheel Angle Cannot Reach Set Point Value ....................................................................................................................................... WP 0033 Error Code 319 - Left-Rear Wheel Angle Cannot Reach Set Point Value ....................................................................................................................................... WP 0033 Error Code 320 - Left-Front Wheel Angle Cannot Reach Set Point Value ....................................................................................................................................... WP 0033 Error Code 321 - Right-Front Wheel is Not Calibrated Correctly ..................................................... WP 0033 Error Code 322 - Right-Rear Wheel is Not Calibrated Correctly ...................................................... WP 0033 Error Code 323 - Left-Rear Wheel is Not Calibrated Correctly ........................................................ WP 0033 Error Code 324 - Left-Front Wheel is Not Calibrated Correctly ........................................................ WP 0033

MISCELLANEOUS TRANSMISSION FAILURE 1. 2. 3. 4. 5. 6. 7. 8. Error Code 618 - Signal from Gear Selector Not Correct ................................................................. WP 0028 Error Code 622 - Feedback Signal from 2WD/4WD Switch Not Correct ............................................................................................................................................. WP 0028 Error Code 745 - Backup Alarm Control Circuit, Short Circuit to Chassis Failure ................................................................................................................................ WP 0028 Error Code 746 - Backup Alarm Control Circuit, Short Circuit to Battery Failure .................................................................................................................................. WP 0028 Error Code 747 - Backup Alarm Control Circuit, Open Circuit Failure .............................................................................................................................................. WP 0028 Error Code 761 - 2WD/4WD Connection Valve Circuit, Short Circuit to Chassis Failure ................................................................................................................. WP 0028 Error Code 762 - 2WD/4WD Connection Valve Circuit, Short Circuit to Battery Failure ................................................................................................................... WP 0028 Error Code 763 - 2WD/4WD Connection Valve Circuit, Open Circuit Failure ................................................................................................................................... WP 0028

OVERLOAD PROTECTION 1. 2. 3. 4. Error Code 130 - Overload Protection System Failure ..................................................................... WP 0010 Error Code 131 - Boom Extension Sensor or Circuit Failure ............................................................ WP 0010 Error Code 132 - Boom Angle Sensor or Circuit Failure .................................................................. WP 0010 Error Code 133 - Left Lift Cylinder Pressure Sensor or Circuit Failure .............................................................................................................................................. WP 0010

0005-9

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TM 10-3930-675-23-1

0005

ERROR CODE SYMPTOM INDEX - Continued Malfunction/Symptom 5. 6. 7. 8. Troubleshooting Procedure

Error Code 134 - Right Lift Cylinder Pressure Sensor or Circuit Failure .............................................................................................................................................. WP 0010 Error Code 135 - Left Lift Cylinder Piston Pressure Sensor or Circuit Failure ................................................................................................................................... WP 0010 Error Code 136 - Right Lift Cylinder Piston Pressure Sensor or Circuit Failure ................................................................................................................................... WP 0010 Error Code 210 - Tophandler Angle Sensor or Circuit Failure ......................................................... WP 0010

STEERING ECU (732), TRANSMISSION ECU (793), AND ENGINE ECU (794) 1. 2. 3. 4. 5. 6. 7. Error Code 300 - Steering ECU (792) Hardware Failure .................................................................. WP 0014 Error Code 841 - Transmission ECU (793) Memory Failure ............................................................ WP 0014 Error Code 843 - Application Error Failure ....................................................................................... WP 0014 Error Code 1111 - Engine ECU (794) Memory Failure .................................................................... WP 0014 Error Code 1341 - Engine ECU (794) Loss of Data Failure ............................................................. WP 0014 Error Code 1343 - Engine ECU (794) Internal Communication Failure .............................................................................................................................................. WP 0014 Error Code 1346 - Engine ECU (794) Software Failure ................................................................... WP 0014

STEERING SENSOR 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. 14. 15. 16. Error Code 301 - Right-Front Wheel Sensor Circuit Failure ............................................................. WP 0034 Error Code 302 - Right-Rear Wheel Sensor Circuit Failure ............................................................. WP 0034 Error Code 303 - Left-Rear Wheel Sensor Circuit Failure ................................................................ WP 0034 Error Code 304 - Left-Front Wheel Sensor Circuit Failure ............................................................... WP 0034 Error Code 305 - Right-Front Wheel Sensor Circuit Failure ............................................................. WP 0034 Error Code 306 - Right-Rear Wheel Sensor Circuit Failure ............................................................. WP 0034 Error Code 307 - Left-Rear Wheel Sensor Circuit Failure ................................................................ WP 0034 Error Code 308 - Left-Front Wheel Sensor Circuit Failure ............................................................... WP 0034 Error Code 309 - Right-Front Wheel Sensor Circuit Failure ............................................................. WP 0034 Error Code 310 - Right-Rear Wheel Sensor Circuit Failure ............................................................. WP 0034 Error Code 311 - Left-Rear Wheel Sensor Circuit Failure ................................................................ WP 0034 Error Code 312 - Left-Front Wheel Sensor Circuit Failure ............................................................... WP 0034 Error Code 313 - Right-Front Wheel Sensor Circuit Failure ............................................................. WP 0034 Error Code 314 - Right-Rear Wheel Sensor Circuit Failure ............................................................. WP 0034 Error Code 315 - Left-Rear Wheel Sensor Circuit Failure ................................................................ WP 0034 Error Code 316 - Left-Front Wheel Sensor Circuit Failure ............................................................... WP 0034

0005-10

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TM 10-3930-675-23-1

0005

ERROR CODE SYMPTOM INDEX - Continued Malfunction/Symptom 17. Troubleshooting Procedure

Error Code 339 - Grounding of Steering Wheel Sensor is Interrupted (RT 240V2 and RT 240V3) ............................................................................................ WP 0034

STEERING VALVE CIRCUIT 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. 14. 15. Error Code 325 - Right-Front Wheel Valve Solenoid, Broken Circuit Failure ................................................................................................................................... WP 0032 Error Code 326 - Right-Rear Wheel Valve Solenoid, Broken Circuit Failure ................................................................................................................................... WP 0032 Error Code 327 - Left-Rear Wheel Valve Solenoid, Broken Circuit Failure ................................................................................................................................... WP 0032 Error Code 328 - Left-Front Wheel Valve Solenoid, Broken Circuit Failure ................................................................................................................................... WP 0032 Error Code 329 - Right-Front Wheel Valve Solenoid, Short Circuit Failure ................................................................................................................................... WP 0032 Error Code 330 - Right-Rear Wheel Valve Solenoid, Short Circuit Failure ................................................................................................................................... WP 0032 Error Code 331 - Left-Rear Wheel Valve Solenoid, Short Circuit Failure .............................................................................................................................................. WP 0032 Error Code 332 - Left-Front Wheel Valve Solenoid, Short Circuit Failure .............................................................................................................................................. WP 0032 Error Code 339 - Grounding of Steering Wheel Sensor is Interrupted (RT 240V2 and RT 240V3) ............................................................................................ WP 0032 Error Code 340 - Hydraulic Steering Pressure Below Threshold [1,450 psi (100 Bar)] ......................................................................................................................... WP 0032 Error Code 341 - Steering Wheel Signal Not Consistent ................................................................. WP 0032 Error Code 342 - One Steering Wheel Signal is Interrupted ............................................................ WP 0032 Error Code 343 - One Steering Wheel Signal is Interrupted ............................................................ WP 0032 Error Code 344 - Both Steering Wheel Signals are Interrupted ....................................................... WP 0032 Error Code 347 - No Steering Mode Selected .................................................................................. WP 0032

TOPHANDLER ELECTRONIC CONTROL UNIT (ECU) (791) 1. 2. 3. 4. 5. Error Code 205 - Memory Failure ..................................................................................................... WP 0011 Error Code 220 - Internal Communication Failure, Connector 2 ...................................................... WP 0011 Error Code 221 - Internal Communication Failure, Connector 2 ...................................................... WP 0011 Error Code 250 - Internal Communication Failure, Connector 3 ...................................................... WP 0011 Error Code 251 - Internal Communication Failure, Connector 3 ...................................................... WP 0011

0005-11

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TM 10-3930-675-23-1

0005

ERROR CODE SYMPTOM INDEX - Continued Malfunction/Symptom Troubleshooting Procedure

TOPHANDLER LEVELING 1. 2. 3. 4. 5. 6. 7. Error Code 128 - Joystick-to-ECU (790) Failure .............................................................................. WP 0043 Error Code 130 - Overload Protection System Failure ..................................................................... WP 0043 Error Code 240 - Tophandler Leveling Locking Control, Wiring Circuit Failure ................................................................................................................................... WP 0043 Error Code 267 - Tophandler Leveling Right, Open Circuit Failure .............................................................................................................................................. WP 0043 Error Code 268 - Tophandler Leveling Right, Short Circuit Failure .............................................................................................................................................. WP 0043 Error Code 270 - Tophandler Leveling Left, Open Circuit Failure .................................................... WP 0043 Error Code 271 - Tophandler Leveling Left, Short Circuit Failure .................................................... WP 0043

TOPHANDLER SIDESHIFT 1. 2. 3. 4. Error Code 225 - Tophandler Sideshift Left, Open Circuit Failure .................................................... WP 0044 Error Code 226 - Tophandler Sideshift Left, Short Circuit Failure .................................................... WP 0044 Error Code 228 - Tophandler Sideshift Right, Open Circuit Failure .............................................................................................................................................. WP 0044 Error Code 229 - Tophandler Sideshift Right, Short Circuit Failure .............................................................................................................................................. WP 0044

TOPHANDLER SLEWING 1. 2. 3. 4. 5. 6. Error Code 128 - Joystick-to-ECU (790) Failure .............................................................................. WP 0041 Error Code 130 - Overload Protection System Failure ..................................................................... WP 0041 Error Code 255 - Tophandler Clockwise Slewing, Wiring Circuit Failure .............................................................................................................................................. WP 0041 Error Code 256 - Tophandler Clockwise Slewing, Component Failure .............................................................................................................................................. WP 0041 Error Code 258 - Tophandler Counterclockwise Slewing, Wiring Circuit Failure ................................................................................................................................... WP 0041 Error Code 259 - Tophandler Counterclockwise Slewing, Component Failure ........................................................................................................................... WP 0041

TOPHANDLER SPREADER 1. 2. Error Code 231 - Tophandler Spreader Opening, Open Circuit Failure .............................................................................................................................................. WP 0045 Error Code 232 - Tophandler Spreader Opening, Short Circuit Failure .............................................................................................................................................. WP 0045

0005-12

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ERROR CODE SYMPTOM INDEX - Continued Malfunction/Symptom 3. 4. Troubleshooting Procedure

Error Code 234 - Tophandler Spreader Closing, Open Circuit Failure .............................................................................................................................................. WP 0045 Error Code 235 - Tophandler Spreader Closing, Short Circuit Failure .............................................................................................................................................. WP 0045

TOPHANDLER TILT 1. 2. 3. 4. 5. 6. 7. Error Code 129 - Joystick-to-ECU (790) Failure .............................................................................. WP 0042 Error Code 130 - Overload Protection System Failure ..................................................................... WP 0042 Error Code 237 - Tophandler Tilt Locking Control, Wiring Circuit Failure .............................................................................................................................................. WP 0042 Error Code 261 - Tophandler Tilt OUT Control, Wiring Circuit Failure .............................................................................................................................................. WP 0042 Error Code 262 - Tophandler Tilt OUT Control, Component Failure .............................................................................................................................................. WP 0042 Error Code 264 - Tophandler Tilt IN Control, Wiring Circuit Failure .............................................................................................................................................. WP 0042 Error Code 265 - Tophandler Tilt IN Control, Component Failure .................................................... WP 0042

TOPHANDLER TWISTLOCKS AND FORKLIFT SENSOR 1. 2. 3. 4. 5. Error Code 212 - Tophandler Left Twistlocks Indication Failure ...................................................... WP 0046 Error Code 213 - Tophandler Right Twistlocks Indication Failure .................................................... WP 0046 Error Code 214 - Tophandler Forklift Sensor Indication Failure ....................................................... WP 0046 Error Code 243 - Tophandler Twistlock Locking Circuit Failure ....................................................... WP 0046 Error Code 246 - Tophandler Twistlock Unlocking Circuit Failure .................................................... WP 0046

TRANSMISSION CLUTCH CIRCUIT 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. Error Code 713 - Clutch K1 Short Circuit to Battery Failure ............................................................. WP 0027 Error Code 714 - Clutch K1 Short Circuit to Chassis Failure ........................................................... WP 0027 Error Code 715 - Clutch K1 Open Circuit Failure ............................................................................. WP 0027 Error Code 716 - Clutch K2 Short Circuit to Battery Failure ............................................................. WP 0027 Error Code 717 - Clutch K2 Short Circuit to Chassis Failure ........................................................... WP 0027 Error Code 718 - Clutch K2 Open Circuit Failure ............................................................................. WP 0027 Error Code 719 - Clutch K3 Open Circuit to Battery Failure ............................................................. WP 0027 Error Code 720 - Clutch K3 Short Circuit to Chassis Failure ........................................................... WP 0027 Error Code 721 - Clutch K3 Open Circuit Failure ............................................................................. WP 0027 Error Code 729 - Clutch K4 Short Circuit to Battery Failure ............................................................. WP 0027

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ERROR CODE SYMPTOM INDEX - Continued Malfunction/Symptom 11. 12. 13. 14. 15. 16. 17. 18. Troubleshooting Procedure

Error Code 730 - Clutch K4 Short Circuit to Chassis Failure ........................................................... WP 0027 Error Code 731 - Clutch K4 Open Circuit Failure ............................................................................. WP 0027 Error Code 732 - Clutch KV Short Circuit to Battery Failure ............................................................ WP 0027 Error Code 733 - Clutch KV Short Circuit to Chassis Failure ........................................................... WP 0027 Error Code 734 - Clutch KV Open Circuit Failure ............................................................................. WP 0027 Error Code 735 - Clutch KR Short Circuit to Battery Failure ............................................................ WP 0027 Error Code 736 - Clutch KR Short Circuit to Chassis Failure ........................................................... WP 0027 Error Code 737 - Clutch KR Open Circuit Failure ............................................................................ WP 0027

TRANSMISSION SPEED SENSORS 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. Error Code 649 - Engine Speed Sensor Failure, Open Circuit or Short Circuit to Battery ................................................................................................................. WP 0026 Error Code 650 - Engine Speed Sensor Failure, Short Circuit to Chassis ............................................................................................................................................ WP 0026 Error Code 651 - Engine Speed Sensor Failure, Logical Error ........................................................ WP 0026 Error Code 652 - Turbine Speed Sensor Failure, Open Circuit or Short Circuit to Battery ................................................................................................................. WP 0026 Error Code 653 - Turbine Speed Sensor Failure, Short Circuit to Chassis ........................................................................................................................................ WP 0026 Error Code 654 - Turbine Speed Sensor Failure, Logical Error ....................................................... WP 0026 Error Code 655 - Internal Speed Sensor Failure, Open Circuit or Short Circuit to Battery ................................................................................................................. WP 0026 Error Code 656 - Internal Speed Sensor Failure, Short Circuit to Chassis ........................................................................................................................................ WP 0026 Error Code 657 - Internal Speed Sensor Failure, Logical Error ....................................................... WP 0026 Error Code 658 - Output Speed Sensor Failure, Open Circuit or Short Circuit to Battery ..................................................................................................................... WP 0026 Error Code 659 - Output Speed Sensor Failure, Short Circuit to Chassis ............................................................................................................................................ WP 0026 Error Code 660 - Output Speed Sensor Failure, Logical Error ......................................................... WP 0026 Error Code 662 - Output Speed Sensor Failure, Logical Speed Error ................................................................................................................................................. WP 0026

TRANSMISSION TEMPERATURE 1. 2. Error Code 637 - Transmission Sump Temperature Sensor Failure, Open Circuit or Short Circuit to Battery ............................................................................... WP 0025 Error Code 638 - Transmission Sump Temperature Sensor Failure, Short Circuit to Chassis ....................................................................................................... WP 0025

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ERROR CODE SYMPTOM INDEX - Continued Malfunction/Symptom Troubleshooting Procedure

3. 4. 5. 6.

Error Code 639 - Converter Output Temperature Sensor Failure, Open Circuit or Short Circuit to Battery ............................................................................... WP 0025 Error Code 640 - Converter Output Temperature Sensor Failure, Short Circuit to Chassis ....................................................................................................... WP 0025 Error Code 783 - Sump Temperature Critical Threshold [212F (100C)] Failure ................................................................................................................................ WP 0025 Error Code 795 - Converter Output Temperature Critical Threshold [248F (120C)] Failure ................................................................................................... WP 0025

ENGINE TROUBLESHOOTING PROCEDURES (NON-ERROR CODE) 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. 14. 15. 16. 17. Engine Will Not Crank ...................................................................................................................... WP 0006 Engine Will Crank but Will Not Start (Exhaust Smoke or No Exhaust Smoke) ............................................................................................................................... WP 0006 Excessive Exhaust Smoke - White ................................................................................................... WP 0006 Excessive Exhaust Smoke - Black ................................................................................................... WP 0006 Engine Acceleration - Poor .............................................................................................................. WP 0006 Engine Deceleration - Poor .............................................................................................................. WP 0006 Engine Performance (Power) - Low ................................................................................................. WP 0006 Engine Runs Rough ......................................................................................................................... WP 0006 Engine Speed Surges (Idle or Under Load) ..................................................................................... WP 0006 Engine Shuts Off Unexpectedly ....................................................................................................... WP 0006 Engine Starts but Will Not Keep Running ......................................................................................... WP 0006 Engine Vibration Excessive .............................................................................................................. WP 0006 Fuel Consumption Excessive ........................................................................................................... WP 0006 Engine Overheats ............................................................................................................................ WP 0006 Engine Oil Pressure - Low ............................................................................................................... WP 0006 Engine Oil Pressure - High ............................................................................................................... WP 0006 Engine Cold Start System Not Working ........................................................................................... WP 0006

ELECTRICAL TROUBLESHOOTING PROCEDURES (NON-ERROR CODE) 1. 2. 3. 4. Headlight(s) (High or Low Beam) Do Not Operate When Switch is Turned On .................................................................................................................................... WP 0006 Front/Rear Side Marker Light(s) or Taillight(s) Do Not Operate When Headlight Switch is Turned On .............................................................................................. WP 0006 Stoplight(s) Do Not Operate When Brake Pedal is Pressed ............................................................ WP 0006 Turn Signals or Emergency Flashers are Not Working .................................................................... WP 0006

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ERROR CODE SYMPTOM INDEX - Continued Malfunction/Symptom Troubleshooting Procedure

5. 6. 7. 8. 9. 10. 11. 12. 13. 14. 15. 16. 17. 18. 19. 20. 21. 22. 23. 24. 25. 26. 27.

Blackout Drive and Marker Lights Do Not Operate When Switch is Turned On .................................................................................................................................... WP 0006 Blackout Stoplights Not Working ...................................................................................................... WP 0006 Horn Will Not Sound When Button is Pressed ................................................................................. WP 0006 Backup Lights/Alarm Does Not Operate When Vehicle Placed in Reverse ........................................................................................................................................ WP 0006 Boom Work Light(s) Do Not Operate When Switch is Turned On .................................................... WP 0006 Tophandler Work Light(s) Do Not Operate When Switch is Turned On ........................................................................................................................................ WP 0006 Infrared (IR) Work Light(s) Do Not Operate When Switch is Turned On. ....................................................................................................................................... WP 0006 Front Windshield Wiper Motor Not Working ..................................................................................... WP 0006 Rear Windshield Wiper Motor Not Working ...................................................................................... WP 0006 Roof Windshield Wiper Motor Not Working ...................................................................................... WP 0006 Windshield Washer Not Working ...................................................................................................... WP 0006 Cab Interior Light Not Working ......................................................................................................... WP 0006 12V Utility Plug Not Working ............................................................................................................ WP 0006 Blower Motor Not Working ............................................................................................................... WP 0006 Heater/Defroster Producing Low or No Heat .................................................................................... WP 0006 A/C System Not Cooling Properly .................................................................................................... WP 0006 Fuel Gauge Not Working Properly ................................................................................................... WP 0006 Drivers ECS Display Screen Will Not Display ................................................................................. WP 0006 After Key On" Functions Not Working (No Crank, Display, etc.). .................................................... WP 0006 Proximity Switches - Tophandler and Cab ....................................................................................... WP 0006 Normal Functions Operate in Blackout Mode ................................................................................... WP 0006 Multiple Boom or Tophandler Functions Not Working (Multiple Error Codes) ..................................................................................................................................... WP 0006 Function(s) Work Uncontrolled ......................................................................................................... WP 0006

BRAKE SYSTEM TROUBLESHOOTING PROCEDURES (NON-ERROR CODE) 1. 2. 3. Braking is Poor or Nonexistent ......................................................................................................... WP 0006 Parking Brake Will Not Release ....................................................................................................... WP 0006 Parking Brake Will Not Engage ........................................................................................................ WP 0006

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ERROR CODE SYMPTOM INDEX - Continued Malfunction/Symptom Troubleshooting Procedure

STEERING SYSTEM TROUBLESHOOTING PROCEDURES (NON-ERROR CODE) 1. Steering Control is Poor or Nonexistent ........................................................................................... WP 0006

OPERATORS CAB TROUBLESHOOTING PROCEDURES (NON-ERROR CODE) 1. Operators Cab Will Not Move To or From Transport Position Properly ............................................................................................................................................ WP 0006

AUXILIARY PUMP TROUBLESHOOTING PROCEDURES (NON-ERROR CODE) 1. Auxiliary Pump Not Working ............................................................................................................. WP 0006

BOOM SYSTEM TROUBLESHOOTING PROCEDURES (NON-ERROR CODE) 1. 2. 3. 4. Boom Will Not Lift or Lower Properly ............................................................................................... WP 0006 Boom Will Not Extend or Retract Properly ....................................................................................... WP 0006 Boom Folding Cylinders Not Working .............................................................................................. WP 0006 Boom Locking Pin Cylinders Not Working ........................................................................................ WP 0006

TOPHANDLER SYSTEM TROUBLESHOOTING PROCEDURES (NON-ERROR CODE) 1. 2. 3. 4. 5. Tophandler Will Not Tilt Forward or Rearward Properly ................................................................... WP 0006 Tophandler Will Not Oscillate (Level) Properly ................................................................................. WP 0006 Tophandler Spreader Will Not Open or Close Properly ................................................................... WP 0006 Tophandler Will Not Rotate Left or Right Properly ........................................................................... WP 0006 Tophandler Twistlocks Will Not Rotate Properly .............................................................................. WP 0006

BOGIE WHEEL SYSTEM TROUBLESHOOTING PROCEDURES (NON-ERROR CODE) 1. Bogie Wheels Will Not Lift or Lower ................................................................................................. WP 0006

FORKLIFT KIT TROUBLESHOOTING PROCEDURES (NON-ERROR CODE) 1. Fork Functions Not Working Properly .............................................................................................. WP 0006

AUTOLUBE SYSTEM NOT LUBRICATING PROPERLY (IF EQUIPPED) TROUBLESHOOTING PROCEDURES (NON-ERROR CODE) 1. 2. Autolube System Not Lubricating Properly (If Equipped) ................................................................. WP 0006 Autolube Pump Not Working (If Equipped) ...................................................................................... WP 0006

END OF WORK PACKAGE

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FIELD MAINTENANCE TROUBLESHOOTING PROCEDURES (NON-ERROR CODE)

INITIAL SETUP: References FO-10 (Volume 2, WP 0272) LO 10-3930-675-13 TM 10-3930-675-10 WP 0004 WP 0008 WP 0013 WP 0018 WP 0020 WP 0026 WP 0047 WP 0050 WP 0051 WP 0052 WP 0069 WP 0070 WP 0071 WP 0072 WP 0073 WP 0076 WP 0077 WP 0080 References (cont.) WP 0081 WP 0083 WP 0088 WP 0093 WP 0094 WP 0095 WP 0103 WP 0109 WP 0110 WP 0114 WP 0115 WP 0123 WP 0127 WP 0129 WP 0133 Volume 2, WP 0159 Volume 2, WP 0194 Volume 2, WP 0195 Volume 2, WP 0267 Volume 2, WP 0272

NOTE
Refer to (WP 0004) for additional troubleshooting guidance, information, and illustrations that locate critical components. TROUBLESHOOTING PROCEDURE ENGINE TROUBLESHOOTING PROCEDURES (NON-ERROR CODE) SYMPTOM ENGINE WILL NOT CRANK MALFUNCTION Transmission Shift Lever is NOT in Neutral. CORRECTIVE ACTION Place transmission shift lever in Neutral.

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ENGINE TROUBLESHOOTING PROCEDURES (NON-ERROR CODE) - Continued MALFUNCTION Master battery switch is off. CORRECTIVE ACTION Place master battery switch to on position. MALFUNCTION Circuit breaker numbers 2 and 8 are tripped. CORRECTIVE ACTION Reset circuit breakers as required (WP 0103). MALFUNCTION Damaged or loose battery connections. CORRECTIVE ACTION

WARNING

To avoid injury, eye protection and acid-resistant gloves must be worn when working around batteries. DO NOT smoke, use open flame, make sparks, or create other ignition sources around batteries. If a battery is giving off gases, it can explode and cause injury to personnel. Remove all jewelry such as rings, ID tags, watches, and bracelets. If jewelry or a tool contacts a battery terminal, a direct short will result in instant heating or electrical shock, damage to equipment, and injury to personnel. Tighten or repair battery connections (WP 0129). MALFUNCTION Check battery voltage. Normal voltage can be 23 to 27V. CORRECTIVE ACTION Test batteries.

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ENGINE TROUBLESHOOTING PROCEDURES (NON-ERROR CODE) - Continued MALFUNCTION No voltage at starter terminal 30. CORRECTIVE ACTION

WARNING

Eye protection must be worn when working under vehicle to avoid injury to personnel. Check wiring back to master battery switch and batteries (Figure 8 (Volume 2, WP 0272)). MALFUNCTION No voltage (24V) at starter solenoid on starter at wire W11 of S terminal while turning the ignition switch to crank (Figure 8 (Volume 2, WP 0272)). CORRECTIVE ACTION 1. 2. Check circuit breaker numbers F50-1 and F50-2 for loose or damaged connections. If voltage is present (24V), replace shorted or damaged starter and solenoid (WP 0093).

T0040JCH

Figure 1. Starter Motor MALFUNCTION Starter relay 360 defective or damage (Volume 2, WP 0267). CORRECTIVE ACTION Replace shorted open or damaged relay (WP 0103).

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0006

ENGINE TROUBLESHOOTING PROCEDURES (NON-ERROR CODE) - Continued MALFUNCTION No voltage (24V) at XK2 pin 7 while turning the ignition switch to crank (Figure 8 (Volume 2, WP 0272)). CORRECTIVE ACTION 1. 2. 3. 4. Check voltage at X8 pin 3 (Figure 8 (Volume 2, WP 0272)). Unplug X8 and check continuity between pin 2 and 3 with the ignition switch turned to crank (Figure 8 (Volume 2, WP 0272)). Repair or replace damaged wires or connectors (Volume 2, WP 0267). Replace damaged or faulty ignition switch (WP 0094).

MALFUNCTION No voltage (24V) at XKI2 pin 4 while turning the ignition switch to crank. CORRECTIVE ACTION 1. 2. 3. 4. Check voltage (24V) at XK2 pin 2 (Figure 8 (Volume 2, WP 0272)) X28 pins 4, 9, and 7 (Figure 9 (Volume 2, WP 0272)) with ignition switch on. Check continuity of shift lever at the loose part of X28 between pin 9 and 7 with the shift lever in Neutral (Figure 9 (Volume 2, WP 0272)). Repair or replace damaged wires or connectors (Volume 2, WP 0267). Replace shift lever (WP 0095).

MALFUNCTION Defective relays. CORRECTIVE ACTION Replace relay (WP 0103). SYMPTOM ENGINE WILL CRANK BUT WILL NOT START (EXHAUST SMOKE OR NO EXHAUST SMOKE) MALFUNCTION Fuel line shutoff valve at fuel filter closed. CORRECTIVE ACTION Open fuel line shutoff valve.

0006-4

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0006

ENGINE TROUBLESHOOTING PROCEDURES (NON-ERROR CODE) - Continued MALFUNCTION Circuit breaker F13 tripped CORRECTIVE ACTION Reset F13 circuit breaker (WP 0013). MALFUNCTION Damaged or leaking fuel lines, hoses, and fittings. CORRECTIVE ACTION Tighten or repair fuel lines, hoses, and fittings (WP 0069). MALFUNCTION Clogged fuel/water separator. CORRECTIVE ACTION Replace fuel/water separator (WP 0076). MALFUNCTION Dirty or clogged air cleaner element. CORRECTIVE ACTION Service or replace air cleaner element (WP 0071). MALFUNCTION Perform cold starting procedures (TM 10-3930-675-10). CORRECTIVE ACTION See cold starting system maintenance (WP 0077). MALFUNCTION Fuel solenoid shutoff valve (FSOV) inoperative. CORRECTIVE ACTION 1. 2. 3. Check for voltage at FSOV (12V). Repair or replace damaged wires or connectors. Replace fuel solenoid shutoff valve (WP 0070).

0006-5

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0006

ENGINE TROUBLESHOOTING PROCEDURES (NON-ERROR CODE) - Continued SYMPTOM EXCESSIVE EXHAUST SMOKE - WHITE MALFUNCTION Low engine operating temperature (ambient temperature). CORRECTIVE ACTION 1. 2. Allow engine to warm to operating temperature. Check cooling fan operation. Enter into EXTRA FUNCT 11(13)" in the diagnostic menu. Fan should run slower in low ambient temperatures.

MALFUNCTION Engine temperature sensor malfunctioning. CORRECTIVE ACTION 1. 2. Perform troubleshooting procedure for ERROR CODES 1144 and 1145 for the coolant temperature sensor (WP 0020). Perform troubleshooting procedure for ERROR CODES 1153 and 1154 for the intake air temperature sensor (WP 0020).

MALFUNCTION Poor quality or wrong type of fuel. CORRECTIVE ACTION 1. 2. SYMPTOM EXCESSIVE EXHAUST SMOKE - BLACK MALFUNCTION Monitor engine operating temperature (low ambient temperature). CORRECTIVE ACTION 1. 2. Allow engine to warm to operating temperature. Check cooling fan operation. Enter into EXTRA FUNCT 11(13)" in the diagnostic menu. Fan should run slower in low ambient temperatures. Compare fuel used with type and grade specifications (TM 10-3930-675-10). lf problem still exists, replace engine assembly (WP 0050).

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ENGINE TROUBLESHOOTING PROCEDURES (NON-ERROR CODE) - Continued MALFUNCTION Engine temperature or pressure sensor malfunctioning. CORRECTIVE ACTION 1. 2. Perform troubleshooting procedure for ERROR CODES 1144 and 1145 for the coolant temperature sensor (WP 0020). Perform troubleshooting procedure for ERROR CODES 1122, 1123, and 1433 for the intake manifold pressure sensor (WP 0022).

MALFUNCTION Check for poor quality or wrong type of fuel. CORRECTIVE ACTION Compare fuel used with type and grade specifications (TM 10-3930-675-10). MALFUNCTION Leaking, damaged, or restricted air intake hoses, lines, and clamps. Dirty or clogged air cleaner element CORRECTIVE ACTION 1. 2. 3. Check quality of fuel, type, and grade. Repair air intake hoses, lines, and clamps (WP 0072). Service or replace air cleaner element (WP 0071).

MALFUNCTION Plugged crankcase ventilation system. CORRECTIVE ACTION Clean crankcase breather and tube (WP 0057). MALFUNCTION Turbocharger malfunction. CORRECTIVE ACTION Replace turbocharger (WP 0073).

0006-7

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0006

ENGINE TROUBLESHOOTING PROCEDURES (NON-ERROR CODE) - Continued

SYMPTOM ENGINE ACCELERATION - POOR MALFUNCTION ERROR CODES or conditions that de-rate engine RPM. CORRECTIVE ACTION Correct ERROR CODE(s)/condition. MALFUNCTION Leaking, damaged, or restricted air intake hoses, lines, and clamps. CORRECTIVE ACTION Repair air intake hoses, lines, and clamps (WP 0072). MALFUNCTION Dirty or clogged air cleaner element. CORRECTIVE ACTION Service air cleaner element (WP 0071). MALFUNCTION Restricted or sticking accelerator pedal. CORRECTIVE ACTION Remove obstructions from accelerator pedal. MALFUNCTION Throttle position sensor inoperative. CORRECTIVE ACTION Test throttle position sensor by performing the troubleshooting steps for ERROR CODES 1131 and 1132 (WP 0008). MALFUNCTION Clogged fuel/water separator. CORRECTIVE ACTION Replace clogged fuel/water separator (WP 0076).

0006-8

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0006

ENGINE TROUBLESHOOTING PROCEDURES (NON-ERROR CODE) - Continued MALFUNCTION Leaking fuel lines, hoses, and fittings. CORRECTIVE ACTION Tighten or repair fuel lines, hoses, and fittings (WP 0069). MALFUNCTION Poor fuel quality. CORRECTIVE ACTION Check quality of fuel, type, and grade. MALFUNCTION Turbocharger malfunction. CORRECTIVE ACTION Replace turbocharger (WP 0073). SYMPTOM ENGINE DECELERATION - POOR MALFUNCTION Restricted or sticking accelerator pedal. CORRECTIVE ACTION Remove obstructions from accelerator pedal. MALFUNCTION Throttle position sensor inoperative. CORRECTIVE ACTION Test throttle position sensor by performing the troubleshooting steps for ERROR CODES 1131 and 1132 (WP 0008). MALFUNCTION Leaking fuel lines, hoses, and fittings. CORRECTIVE ACTION Tighten or repair fuel lines, hoses, and fittings (WP 0069).

0006-9

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ENGINE TROUBLESHOOTING PROCEDURES (NON-ERROR CODE) - Continued MALFUNCTION Restrictions in fuel lines, hoses, and fittings. CORRECTIVE ACTION Replace any damaged or restricted fuel line, hose, or fitting (WP 0069). MALFUNCTION Turbocharger malfunction. CORRECTIVE ACTION Replace turbocharger (WP 0073). SYMPTOM ENGINE PERFORMANCE (POWER) - LOW MALFUNCTION ERROR CODES or conditions that de-rate engine RPM. CORRECTIVE ACTION Correct ERROR CODE(s)/condition. MALFUNCTION Parasitic loads on engine. CORRECTIVE ACTION Check for brakes dragging, hydraulic malfunctions, etc. MALFUNCTION Incorrect engine oil level. CORRECTIVE ACTION Verify engine oil is not overfilled (WP 0047). MALFUNCTION Clogged fuel/water separator. CORRECTIVE ACTION Replace clogged fuel/water separator (WP 0076).

0006-10

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ENGINE TROUBLESHOOTING PROCEDURES (NON-ERROR CODE) - Continued MALFUNCTION Leaking fuel lines, hoses, and fittings, or restricted fuel lines (supply and return). CORRECTIVE ACTION Tighten or repair fuel lines, hoses, and fittings (WP 0069). MALFUNCTION Poor fuel quality. CORRECTIVE ACTION Check quality of fuel, type, and grade. MALFUNCTION Leaking, damaged, or restricted air intake hoses, lines, and clamps. CORRECTIVE ACTION Tighten or repair air intake hoses, lines, and clamps (WP 0072). MALFUNCTION Dirty or clogged air cleaner element. CORRECTIVE ACTION Service air cleaner element (WP 0071). MALFUNCTION Restricted or sticking accelerator pedal. CORRECTIVE ACTION Remove obstructions from accelerator pedal. MALFUNCTION Throttle position sensor inoperative. CORRECTIVE ACTION Test throttle position sensor by performing the troubleshooting steps for ERROR CODES 1131 and 1132 (WP 0008).

0006-11

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0006

ENGINE TROUBLESHOOTING PROCEDURES (NON-ERROR CODE) - Continued

SYMPTOM ENGINE RUNS ROUGH MALFUNCTION Monitor engine operating temperature (low ambient temperature). CORRECTIVE ACTION 1. 2. Allow engine to warm to operating temperature. Incorrect cooling fan operation. Enter into EXTRA FUNCT 11(13)" in the diagnostic menu. Fan should run slower in low ambient temperatures.

MALFUNCTION Loose or damaged engine mounts. CORRECTIVE ACTION 1. 2. Tighten loose engine mounts. Replace engine mounts (WP 0051).

MALFUNCTION Clogged fuel/water separator or leaking fuel lines, hoses, and fittings that may allow air into fuel system. Restricted fuel lines (supply and return). CORRECTIVE ACTION 1. 2. Tighten or repair fuel lines, hoses, and fittings (WP 0069). Replace clogged fuel/water separator (WP 0076).

MALFUNCTION Poor fuel quality. CORRECTIVE ACTION Check quality of fuel, type, and grade. MALFUNCTION Engine Position Sensor (EPS) or circuit malfunction. CORRECTIVE ACTION Perform troubleshooting procedures for ERROR CODES 1115 and 1121 (WP 0018).

0006-12

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0006

ENGINE TROUBLESHOOTING PROCEDURES (NON-ERROR CODE) - Continued MALFUNCTION Turbocharger malfunction. CORRECTIVE ACTION Replace turbocharger (WP 0073). SYMPTOM ENGINE SPEED SURGES (IDLE OR UNDER LOAD) MALFUNCTION Engine idle speed set too low or idling with excessive load. CORRECTIVE ACTION Monitor idle speed; should be around 700 RPM. Check for excessive hydraulic loads at idle. MALFUNCTION Clogged fuel/water separator or leaking fuel lines, hoses, and fittings. Restricted fuel lines (supply and return). CORRECTIVE ACTION 1. 2. Tighten or repair fuel lines, hoses, and fittings (WP 0069). Replace clogged fuel/water separator (WP 0076).

MALFUNCTION Poor fuel quality. CORRECTIVE ACTION Check quality of fuel, type, and grade. MALFUNCTION Restricted or sticking accelerator pedal. CORRECTIVE ACTION Remove obstructions from accelerator pedal.

0006-13

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0006

ENGINE TROUBLESHOOTING PROCEDURES (NON-ERROR CODE) - Continued MALFUNCTION Throttle position sensor inoperative. CORRECTIVE ACTION Test throttle position sensor by performing the troubleshooting steps for ERROR CODES 1131 and 1132 (WP 0008). MALFUNCTION Leaking, damaged, or restricted air intake hoses, lines, and clamps. CORRECTIVE ACTION Tighten or repair air intake hoses, lines, and clamps (WP 0072). MALFUNCTION Dirty or clogged air cleaner element. CORRECTIVE ACTION Service air cleaner element (WP 0071). MALFUNCTION Engine Position Sensor (EPS) circuit malfunction CORRECTIVE ACTION Perform troubleshooting procedures for ERROR CODES 1115 and 1121 (WP 0018). SYMPTOM ENGINE SHUTS OFF UNEXPECTEDLY MALFUNCTION ERROR CODES that de-rate engine RPM. CORRECTIVE ACTION Correct ERROR CODE using the troubleshooting procedures. MALFUNCTION Incorrect battery voltage. CORRECTIVE ACTION Service batteries and connections (WP 0129).

0006-14

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ENGINE TROUBLESHOOTING PROCEDURES (NON-ERROR CODE) - Continued MALFUNCTION Circuit breakers F13, F4, and F5 tripped. CORRECTIVE ACTION Replace faulty circuit breaker (WP 0103). MALFUNCTION No voltage at X16 pin 9 and EUC (794) pin 38 with the ignition on. CORRECTIVE ACTION Repair or replace wires or connectors (Figure 3 (Volume 2, WP 0272)). MALFUNCTION Clogged fuel/water separator or leaking fuel lines, hoses, and fittings. CORRECTIVE ACTION Replace clogged fuel/water separator (WP 0076). MALFUNCTION Check for restricted fuel lines (supply and return). CORRECTIVE ACTION Tighten or repair fuel lines, hoses, and fittings (WP 0069). MALFUNCTION Turbocharger malfunction. CORRECTIVE ACTION Replace turbocharger (WP 0073). SYMPTOM ENGINE STARTS BUT WILL NOT KEEP RUNNING MALFUNCTION ERROR CODES that de-rate engine RPM and shut down after 30 seconds (RT 240V1R, RT 240V2 and RT 240V3). CORRECTIVE ACTION Correct ERROR CODE using the troubleshooting procedures.

0006-15

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ENGINE TROUBLESHOOTING PROCEDURES (NON-ERROR CODE) - Continued MALFUNCTION Incorrect battery voltage. CORRECTIVE ACTION Service batteries and connections. MALFUNCTION Tripped circuit breakers F13, F4, and F5. CORRECTIVE ACTION Replace faulty circuit breaker (WP 0103). MALFUNCTION No voltage at X16 pin 9 and EUC (794) pin 38 with the ignition on. CORRECTIVE ACTION Repair or replace wires or connectors (Volume 2, WP 0267). MALFUNCTION Parasitic loads on engine. CORRECTIVE ACTION Check for hydraulic malfunctions, etc., that cause loading on engine. MALFUNCTION Poor quality or wrong type of fuel. CORRECTIVE ACTION Compare fuel used with type and grade specifications (TM 10-3930-675-10). SYMPTOM ENGINE VIBRATION EXCESSIVE MALFUNCTION Engine misfiring. CORRECTIVE ACTION Perform troubleshooting procedure for Engine Runs Rough in this work package.

0006-16

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0006

ENGINE TROUBLESHOOTING PROCEDURES (NON-ERROR CODE) - Continued MALFUNCTION Belt-driven accessories malfunctioning. CORRECTIVE ACTION Check alternator and air conditioner compressor operation. MALFUNCTION Loose or damaged engine mounts. CORRECTIVE ACTION 1. 2. Tighten loose engine mounts. Replace engine mounts (WP 0051).

MALFUNCTION Loose or damaged engine vibration damper. CORRECTIVE ACTION 1. 2. SYMPTOM FUEL CONSUMPTION EXCESSIVE MALFUNCTION Leaking fuel lines, hoses, and fittings. CORRECTIVE ACTION Tighten or repair fuel lines, hoses, and fittings (WP 0069). MALFUNCTION Poor quality or wrong type of fuel. CORRECTIVE ACTION Compare fuel used with type and grade specifications (TM 10-3930-675-10). Tighten loose engine vibration damper. Replace vibration damper (WP 0053).

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ENGINE TROUBLESHOOTING PROCEDURES (NON-ERROR CODE) - Continued MALFUNCTION Incorrect oil level. CORRECTIVE ACTION Verify engine oil is not overfilled (WP 0047). MALFUNCTION Leaking, damaged, or restricted air intake hoses, lines, and clamps. CORRECTIVE ACTION Tighten or repair air intake hoses, lines, and clamps (WP 0072). MALFUNCTION Dirty or clogged air cleaner element. CORRECTIVE ACTION Service air cleaner element (WP 0071). MALFUNCTION Turbocharger malfunction. CORRECTIVE ACTION Replace turbocharger (WP 0073). SYMPTOM ENGINE OVERHEATS MALFUNCTION Coolant level low. CORRECTIVE ACTION Fill the coolant to the proper level in the coolant expansion tank (LO 10-3930-675-13). MALFUNCTION Incorrect engine oil level. CORRECTIVE ACTION Verify engine oil is not overfilled (LO 10-3930-675-13).

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ENGINE TROUBLESHOOTING PROCEDURES (NON-ERROR CODE) - Continued MALFUNCTION Radiator, radiator cap, and louvers damaged or obstructed. CORRECTIVE ACTION 1. 2. 3. Clean dirt and debris from radiator and louvers. Replace leaking radiator cap (WP 0080). Replace louvers (WP 0081).

MALFUNCTION Coolant system hoses loose, damaged, leaking, or collapsed. CORRECTIVE ACTION 1. 2. Inspect and tighten any loose clamps. Replace any damaged, leaking, or collapsed hoses (WP 0083).

MALFUNCTION Incorrect cooling fan operation. CORRECTIVE ACTION 1. 2. Start engine and enter into EXTRA FUNCT 11(13)" in the diagnostic menu. Change the fan speed and observe if fan speed changes properly (0%, 33%, 66%, and 100%). If fan does not change speeds, check hydraulic pressure of engine driven pump (WP 0214).

MALFUNCTION Incorrect status of fording switch. CORRECTIVE ACTION 1. 2. Enter into EXTRA FUNCT 4(13)" in the diagnostic menu. WATER LEVEL" should indicate 1". If 0" is indicated, perform troubleshooting of fording switch circuit (Figure 7 (Volume 2, WP 0272)).

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ENGINE TROUBLESHOOTING PROCEDURES (NON-ERROR CODE) - Continued MALFUNCTION Incorrect thermostat operation. CORRECTIVE ACTION 1. 2. 3. 4. 5. With the engine cold, connect a 3/8 in. (10 mm) hose to the barbed bleeder valve on the metal line coming from top of hose to radiator thermostat housing. Open the coolant expansion tank and place the other end of the hose in the top of the tank and hold. Open the bleeder valve. Start the engine and observe the coolant flow from the hose. Coolant flow should not exceed 4 oz (0.12 L) per minute. Run the engine until it reaches operating temperature. The coolant flow should increase when the thermostat opens. Replace the thermostat if the coolant does not flow at operating temperature or flow exceeds 4 oz (0.12 L) per minute with the engine cold.

MALFUNCTION Incorrect water pump operation. CORRECTIVE ACTION 1. 2. Inspect water pump for leakage at weep hole. Unplug the weep hole if found plugged with debris. If no flow is observed in the coolant expansion tank or the pump is leaking, replace water pump (WP 0088).

SYMPTOM ENGINE OIL PRESSURE - LOW MALFUNCTION ERROR CODES that de-rate engine RPM. CORRECTIVE ACTION Correct ERROR CODE using the troubleshooting procedures. MALFUNCTION Engine oil is contaminated. CORRECTIVE ACTION 1. 2. Take an oil sample and have it tested for contaminants, type, and specifications (WP 0047). Change oil and filter (LO 10-3930-675-13).

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ENGINE TROUBLESHOOTING PROCEDURES (NON-ERROR CODE) - Continued

SYMPTOM ENGINE OIL PRESSURE - HIGH MALFUNCTION Engine oil is contaminated. CORRECTIVE ACTION Replace engine oil and filter (LO 10-3930-675-13). SYMPTOM ENGINE COLD START SYSTEM NOT WORKING MALFUNCTION Circuit breaker F17 tripped. CORRECTIVE ACTION 1. 2. Reset circuit breaker. Replace faulty circuit breaker (WP 0103).

MALFUNCTION Cold start ether canister, system tubing, activation solenoid, or engine temperature sensor damaged. CORRECTIVE ACTION 1. 2. 3. Replace empty or missing canister (WP 0077). Replace any damaged or disconnected tubing (WP 0077). Replace damaged activation solenoid or engine temperature sensor (WP 0077).

MALFUNCTION Cold start system wiring damaged. CORRECTIVE ACTION Repair any loose or missing connections (Volume 2, WP 0267).

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ENGINE TROUBLESHOOTING PROCEDURES (NON-ERROR CODE) - Continued MALFUNCTION Cold start system inoperative. CORRECTIVE ACTION 1. 2. 3. 4. 5. 6. The resistance should be 3 to 4 Ohms. Unplug the activation solenoid and check resistance between the two pins. Check continuity between each pin and ground. Unplug the engine temperature sensor and check continuity between the two pins. There should not be any continuity. There should be continuity up to 120F (49C). Replace open or shorted activation solenoid or engine temperature sensor (WP 0077).

MALFUNCTION Incorrect cold start system voltage. CORRECTIVE ACTION 1. 2. 3. 4. 5. 6. If voltage (24V) is found at activation solenoid, replace activation solenoid (WP 0077). If no voltage (24V) is found, check continuity of wires 162, W12B, and W12A where they connect to 360 start solenoid pin 85. Remove the ether canister from activation solenoid. Press the cold start switch. You should hear the activation solenoid click". Unplug the activation solenoid and check for voltage (24V) while pressing the cold start system switch. Enter EXTRA FUNC 8(13)" in the diagnostic menu. a. b. If 1", go to Incorrect voltage (24V) at X16 pin 2 with ignition on". If 1" indication does not appear, go to Incorrect voltage (24V) at X67 pin 1&4 with ignition on".

MALFUNCTION Incorrect voltage (24V) at X67 pin 1 and 4 with the ignition on (Figure 16 (Volume 2, WP 0272)). CORRECTIVE ACTION 1. 2. 3. 4. 5. If no voltage is found at X67 pin 1, check circuit breaker F17 and continuity of wire A678 and A671 (Figure 15 (Volume 2, WP 0272)). Replace faulty circuit breaker (WP 0103). If no voltage (24V) is found at X67 pin 4, check continuity of wires 671, 671A, 674, A479, 479, and A17415, and test continuity of cold start system switch (Figure 16 (Volume 2, WP 0272)). Repair or replace damaged wires or connectors (Volume 2, WP 0267). Replace cold start system switch if faulty (WP 0094).

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ENGINE TROUBLESHOOTING PROCEDURES (NON-ERROR CODE) - Continued MALFUNCTION Incorrect voltage (24V) at X16 pin 2 with the ignition on (Figure 16 (Volume 2, WP 0272)). CORRECTIVE ACTION 1. 2. If no voltage (24V) is found at X16 pin 2, check continuity of wires A17415A, 16011, A1508, 294, and A162A (Figure 16 (Volume 2, WP 0272)). Repair or replace damaged wires or connectors (Volume 2, WP 0267).

Electrical Troubleshooting Procedures (Non-Error Code) SYMPTOM HEADLIGHT(S) (HIGH OR LOW BEAM) DO NOT OPERATE WHEN SWITCH IS TURNED ON MALFUNCTION Incorrect position of blackout drive/marker light switch. CORRECTIVE ACTION Place blackout drive/marker light switch in OFF position. MALFUNCTION Circuit breakers F16, F18, F19, F20, and F21 tripped. CORRECTIVE ACTION 1. 2. Reset circuit breakers as required. Replace damaged or faulty circuit breaker (WP 0103).

MALFUNCTION Headlights are damaged or burned out lamps. CORRECTIVE ACTION 1. 2. Replace burned out lamps (WP 0109). Replace damaged headlight (WP 0109).

MALFUNCTION Headlight wiring harnesses and connectors are damaged. CORRECTIVE ACTION Repair or replace damaged harnesses or connectors (Volume 2, WP 0267).

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Electrical Troubleshooting Procedures (Non-Error Code) - Continued MALFUNCTION No voltage (24V) at X6 pin 2 with the headlight switch turned on. CORRECTIVE ACTION 1. 2. Replace damaged or faulty switch (WP 0094). Repair or replace damaged wires or connectors (Volume 2, WP 0267).

MALFUNCTION No voltage (24V) at X19 pin 5 with the headlight switch turned on. CORRECTIVE ACTION 1. 2. Check continuity of wire A62 (Figure 14 (Volume 2, WP 0272)). Repair or replace damaged wires or connectors (Volume 2, WP 0267).

MALFUNCTION No voltage (24V) at X19 pin 6 and 7 with the headlight switch turned on and operating the HI/LO beams. CORRECTIVE ACTION 1. 2. 3. 4. Check continuity of wires 195, 196, and 197 (Figure 14 (Volume 2, WP 0272)). Repair or replace damaged wires or connectors (Volume 2, WP 0267). Check accessory control lever for damage and continuity (Figure 14 (Volume 2, WP 0272)). Replace damaged or faulty accessory control lever (Volume 2, WP 0167).

MALFUNCTION No voltage (24V) at X11 pin 7 and X12 pin 6 with the headlight switch turned on and in LOW beam. CORRECTIVE ACTION 1. 2. Repair or replace damaged wires or connectors (Volume 2, WP 0267). Replace damaged or faulty circuit breaker (Volume 2, WP 0267).

MALFUNCTION No voltage (24V) at X11 pin 8 and X12 pin 8 with the headlight switch turned on and in HIGH beam. CORRECTIVE ACTION 1. 2. Repair or replace damaged wires or connectors (Volume 2, WP 0267). Replace damaged or faulty circuit breaker (WP 0103).

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Electrical Troubleshooting Procedures (Non-Error Code) - Continued SYMPTOM FRONT/REAR SIDE MARKER LIGHT(S) OR TAILLIGHTS(S) DO NOT OPERATE WHEN HEADLIGHT SWITCH IS TURNED ON MALFUNCTION Incorrect position of blackout drive/marker light switch. CORRECTIVE ACTION Place blackout drive/marker light switch in OFF position. MALFUNCTION Circuit breakers F22 and F23 are tripped. CORRECTIVE ACTION 1. 2. 3. Reset circuit breakers as required. Replace any shorted or grounded harnesses (Volume 2, WP 0267). Replace damaged or faulty circuit breaker (WP 0103).

MALFUNCTION Marker and taillights are damaged or burned out lamps. CORRECTIVE ACTION 1. 2. Replace burned out lamps (WP 0109). Replace damaged marker or taillights (WP 0109).

MALFUNCTION Marker and taillight wiring harnesses and connectors are damaged. CORRECTIVE ACTION Repair or replace damaged harnesses or connectors (Volume 2, WP 0267). MALFUNCTION No voltage (24V) at X6 pin 1 with the headlight switch turned on (headlights working). CORRECTIVE ACTION 1. 2. 3. Remove headlight switch from the instrument panel and check for continuity. Replace damaged or faulty switch (WP 0094). Repair or replace damaged wires or connectors (Volume 2, WP 0267).

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Electrical Troubleshooting Procedures (Non-Error Code) - Continued MALFUNCTION No voltage (24V) at F22 and F23 with the headlight switch on. CORRECTIVE ACTION Replace damaged or faulty circuit breaker (WP 0103). MALFUNCTION No voltage (24V) at X11 pin 1, X12 pin 7, X14 pin 2, X14 pin 9, X15 pin 2, and X15 pin 7 with the headlight switch turned on. CORRECTIVE ACTION 1. 2. Check continuity, using the wiring diagram, of wires A149, A157, A149B, A149A, A157A, and A157B (Figure 14 (Volume 2, WP 0272)). Repair or replace damaged wires or connectors (Volume 2, WP 0267).

MALFUNCTION Check continuity, using the wiring diagram, of the marker and taillight wiring harnesses from X11 pin 1 to left front marker, X12 pin 7 to the right front marker, X15 pin 2 to the left rear marker, X14 pin 2 to the right rear marker, X14 pin 9 to the right taillight, and X15 pin 7 to the left taillight. CORRECTIVE ACTION Replace damaged or open harness or connectors (Volume 2, WP 0267). SYMPTOM STOPLIGHT(S) DO NOT OPERATE WHEN BRAKE PEDAL IS PRESSED MALFUNCTION Incorrect position of blackout drive/marker light switch. CORRECTIVE ACTION Place blackout drive/marker light switch in OFF position.

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Electrical Troubleshooting Procedures (Non-Error Code) - Continued MALFUNCTION Circuit breaker F10 tripped. CORRECTIVE ACTION 1. 2. Reset circuit breaker as required. Replace damaged or faulty circuit breaker (Volume 2, WP 0267).

MALFUNCTION Damaged or burned out lamps. CORRECTIVE ACTION 1. 2. Replace burned out lamps (WP 0109). Replace damaged stoplights (Volume 2, WP 0159).

MALFUNCTION Stoplight wiring harnesses and connectors are damaged. CORRECTIVE ACTION Repair or replace damaged harnesses or connectors (Volume 2, WP 0267). MALFUNCTION No voltage (24V) at X26 pin 2 and 3 with the ignition on and the brake pedal depressed. (Ensure the hydraulic brake pressure is built up.) CORRECTIVE ACTION 1. 2. 3. Remove the kick panel in front of the steering column and check brake light switch 216 for continuity while depressing the brake pedal (Volume 2, WP 0159). Replace damaged or faulty switch (Volume 2, WP 0159). Repair or replace damaged wires or connectors (Volume 2, WP 0267).

MALFUNCTION No voltage (24V) at XK13 pin 6 and 9 with the ignition on and the brake pedal depressed. (Ensure the hydraulic brake pressure is built up.) CORRECTIVE ACTION Replace damaged or faulty relay 3010 (WP 0103).

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Electrical Troubleshooting Procedures (Non-Error Code) - Continued MALFUNCTION No continuity between XK13 pin 9 and 3010 terminal 30, and XK 13 pin 6 and 3010 terminal 87a. CORRECTIVE ACTION Replace damaged or faulty relay board (Volume 2, WP 0267). MALFUNCTION No voltage (24V) at XK14 pin 4 and 7 with the ignition on and the brake pedal depressed. (Ensure the hydraulic brake pressure is built up). CORRECTIVE ACTION Replace relay 3015R (Volume 2, WP 0267). MALFUNCTION No continuity of wires A036 and A263 (Figure 14 & Figure 10 (Volume 2, WP 0272)). CORRECTIVE ACTION Repair or replace damaged wires or connectors (Volume 2, WP 0267). MALFUNCTION No continuity between XK14 pin 7 and 3015R terminal 30, and XK14 pin 4 and 3015R terminal 87a with the 3015R relay removed. CORRECTIVE ACTION Replace relay board (WP 0103). MALFUNCTION No voltage (24V) at XK15 pin 4 and 7 with the ignition on and the brake pedal depressed. (Ensure the hydraulic brake pressure is built up.) CORRECTIVE ACTION 1. 2. 3. Check continuity of wires A036 and A263 (Figure 14 & Figure 10 (Volume 2, WP 0272)). Replace damaged or faulty relay (WP 0103). Repair or replace damaged wires or connectors (Volume 2, WP 0267).

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Electrical Troubleshooting Procedures (Non-Error Code) - Continued MALFUNCTION Incorrect continuity between XK15 pin 7 and 3015L terminal 30, and XK15 pin 4 and 3015L terminal 87a with the 3015L relay removed. CORRECTIVE ACTION Replace damaged or faulty relay board (WP 0103). MALFUNCTION No continuity of the stoplight wiring harnesses from XK14 pin 7 to the right stoplight and XK15 pin 7 to the left stoplight (Figure 14 (Volume 2, WP 0272)). CORRECTIVE ACTION Replace damaged or open harness or connectors (Volume 2, WP 0267). SYMPTOM TURN SIGNALS OR EMERGENCY FLASHERS ARE NOT WORKING MALFUNCTION Incorrect position of blackout drive/marker light switch. CORRECTIVE ACTION Place blackout drive/marker light switch in OFF position. MALFUNCTION Circuit breakers F2 and F6 are tripped. CORRECTIVE ACTION 1. 2. Reset circuit breaker as required. If breaker does not reset, use the wiring diagram to check circuit for short to ground (Volume 2, WP 0272). Replace any shorted or grounded harnesses (Volume 2, WP 0267).

MALFUNCTION Inspect signal lights for damaged or burned out lamps. CORRECTIVE ACTION 1. 2. Replace burned out lamps (WP 0109). Replace damaged signal lights (WP 0109).

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Electrical Troubleshooting Procedures (Non-Error Code) - Continued MALFUNCTION Signal light wiring harnesses and connectors are damaged. CORRECTIVE ACTION Repair or replace damaged harnesses or connectors (Volume 2, WP 0267). MALFUNCTION No voltage (24V) at X19 pin 1, 2, and 3 while operating the turn signal lever. There should be voltage (24V) at pin 2 when signaling left and at pin 3 for right. CORRECTIVE ACTION 1. 2. Check circuit breaker F6 and wire A191 (Figure 14 (Volume 2, WP 0272)). If no voltage (24V) is found at X19 pin 2 or 3 while operating the signal lever; check accessory control lever for damage and continuity and check continuity of wires 191, 192, and 193 (Figure 14 (Volume 2, WP 0272)). Replace damaged or faulty accessory control lever (Volume 2, WP 0167). Repair or replace damaged wires or connectors (Volume 2, WP 0267).

3. 4.

MALFUNCTION No voltage (24V) at XK14 pin 8 and XK15 pin 8 while operating the turn signal lever. There should be voltage at pin XK15 pin 8 when signaling left and at XK14 pin 8 for right. CORRECTIVE ACTION 1. 2. Check continuity of wires A192 and A193 (Figure 14 (Volume 2, WP 0272)). Repair or replace damaged wires or connectors (Volume 2, WP 0267).

MALFUNCTION No voltage (24V) at XK1 pin 5 and pin 1 while operating the turn signals. There should be constant voltage at pin 5 and flashing voltage at pin 1. CORRECTIVE ACTION 1. 2. Check blackout drive/marker light switch and circuit from circuit breaker F2 (Figure 13 (Volume 2, WP 0272)). Replace damaged or faulty 323 flasher relay (WP 0103).

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Electrical Troubleshooting Procedures (Non-Error Code) - Continued MALFUNCTION No continuity, with 323 flasher relay removed, between XK1 pin 5 and 323 terminal 49, and XK1 pin 1 and 323 terminal 49a, and XK1 pin 2 and 323 terminal 31. CORRECTIVE ACTION Replace damaged or faulty relay board (WP 0103). MALFUNCTION No voltage (24V) at XK14 pin 3 and XK15 pin 3 while operating the turn signals. There should be flashing voltage at XK14 pin 3 for signaling right and a XK15 pin 3 for left. CORRECTIVE ACTION Replace damaged or faulty relay (WP 0103). MALFUNCTION No voltage (24V) at XK14 pin 7 and XK15 pin 7 while operating the turn signals. There should be flashing voltage at XK14 pin 7 for signaling right and at XK15 pin 7 for left. CORRECTIVE ACTION Replace damaged or faulty relay (WP 0103). MALFUNCTION No continuity of the signal wiring harnesses from XK14 pin 7 to the right rear and XK14 pin 3 for the right front, and XK15 pin 7 to the left rear and XK15 pin 3 for the left front (Figure 14 (Volume 2, WP 0272)). CORRECTIVE ACTION Replace damaged or open harness or connectors (Volume 2, WP 0267). MALFUNCTION No voltage (24V) at X6 pin 4, 5, and 6 with the emergency flasher switch depressed. CORRECTIVE ACTION 1. 2. SYMPTOM BLACKOUT DRIVE AND MARKER LIGHTS DO NOT OPERATE WHEN SWITCH IS TURNED ON Check continuity, using the wiring diagram, of wires 64, 65, and 66 (Figure 14 (Volume 2, WP 0272)). Replace damaged or faulty switch (WP 0094).

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Electrical Troubleshooting Procedures (Non-Error Code) - Continued MALFUNCTION Incorrect position of blackout drive/marker light switch. CORRECTIVE ACTION Place blackout drive/marker light switch in ON position. MALFUNCTION Circuit breakers F24 and F25 are tripped. CORRECTIVE ACTION 1. 2. Reset circuit breakers as required. If any breaker does not reset, use the wiring diagram to check circuit for short to ground (Figure 14 (Volume 2, WP 0272)). Replace any shorted or grounded harnesses (Volume 2, WP 0267). Replace damaged or faulty circuit breaker (WP 0103).

3.

MALFUNCTION Blackout drive and marker lights damaged or burned out lamps. CORRECTIVE ACTION 1. 2. Replace burned out lamps (WP 0109). Replace damaged blackout lights (WP 0109).

MALFUNCTION Blackout drive and marker light wiring harnesses and connectors are damaged. CORRECTIVE ACTION Repair or replace damaged harnesses or connectors (Volume 2, WP 0267). MALFUNCTION No voltage (24V) at X7 pin 9 and 6 with the blackout drive marker light switch turned on. CORRECTIVE ACTION 1. 2. 3. Check the continuity of the wires A79, 79, 76 and A76, (Figure 14 (Volume 2, WP 0272)). Repair or replace damaged wires or connectors (Volume 2, WP 0267). Replace damaged or faulty switch (WP 0094).

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Electrical Troubleshooting Procedures (Non-Error Code) - Continued MALFUNCTION No voltage (24V) at X11 pin 3, X11 pin 9, X12 pin 1, X14 pin 1, and X15 pin 1 with the blackout drive marker light switch turned on. CORRECTIVE ACTION 1. 2. Check continuity of wires A113, A153, A119, A121, and A141 (Figure 14 (Volume 2, WP 0272)). Repair or replace damaged wires or connectors (Volume 2, WP 0267).

MALFUNCTION No continuity of the blackout drive marker light wiring harnesses from X11 pin 3 to left front blackout position light, X12 pin 1 to right front blackout position light, X14 pin 1 to right blackout taillight, X15 pin 3 to the left blackout taillight, and X11 pin 9 to blackout headlight. CORRECTIVE ACTION Replace damaged or open harness or connectors (Volume 2, WP 0267). SYMPTOM BLACKOUT STOPLIGHTS NOT WORKING MALFUNCTION Check the operation of the normal stoplights. CORRECTIVE ACTION If stoplights are not working, perform troubleshooting procedure for Stop Light (s) Do Not Operate When Brake Pedal is Pressed" in this work package. MALFUNCTION Incorrect position of blackout drive/marker light switch. CORRECTIVE ACTION Place blackout drive/marker light switch in ON position. MALFUNCTION Stoplights are damaged or burned out lamps. CORRECTIVE ACTION 1. 2. Replace burned out lamps (WP 0109). Replace damaged blackout stoplights (WP 0109).

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Electrical Troubleshooting Procedures (Non-Error Code) - Continued MALFUNCTION Blackout stoplight wiring harnesses or connectors damaged. CORRECTIVE ACTION Repair or replace damaged harnesses or connectors (Volume 2, WP 0267). MALFUNCTION No voltage (24V) at XK13 pin 3 with the ignition on and the brake pedal depressed. (Ensure the hydraulic brake pressure is built up). CORRECTIVE ACTION Replace damaged or faulty relay (WP 0103). MALFUNCTION No continuity of the blackout drive marker light wiring harnesses from XK13 pin 3 to right and left blackout stoplights. (Figure 14 (Volume 2, WP 0272)). CORRECTIVE ACTION Replace damaged or open harness or connectors (Volume 2, WP 0267). SYMPTOM HORN WILL NOT SOUND WHEN BUTTON IS PRESSED MALFUNCTION Incorrect position of blackout drive/marker light switch. CORRECTIVE ACTION Place blackout drive/marker light switch in OFF position. MALFUNCTION Check circuit breaker F9 tripped. CORRECTIVE ACTION Reset circuit breaker as required. MALFUNCTION Horn, connectors, or wiring damaged. CORRECTIVE ACTION 1. Test horn using 24V source.

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Electrical Troubleshooting Procedures (Non-Error Code) - Continued CORRECTIVE ACTION - Continued 2. 3. Repair or replace damaged harnesses or connectors (Volume 2, WP 0267). Replace damaged horn (WP 0127).

MALFUNCTION No voltage (24V) at X20 pin 1 and 2 with the horn switch depressed. CORRECTIVE ACTION 1. 2. 3. Check continuity of wire A201 (Figure 11 (Volume 2, WP 0272)). If no voltage (24V) is found at X20 pin 2, check accessory control lever for damage and continuity (Figure 13 (Volume 2, WP 0272)). Replace damaged or faulty accessory control lever (Volume 2, WP 0167).

MALFUNCTION No voltage (24V) at X13 pin 9 with the horn switch depressed. CORRECTIVE ACTION 1. 2. 3. Check continuity of wires 202, A202, and A139 (Figure 13 (Volume 2, WP 0272)). Repair or replace damaged wires or connectors (Volume 2, WP 0267). Replace damaged or faulty relay (WP 0103).

MALFUNCTION No voltage (24V) between the two pins of the harness with the horn switch depressed. CORRECTIVE ACTION 1. 2. SYMPTOM BACKUP LIGHTS/ALARM DOES NOT OPERATE WHEN VEHICLE PLACED IN REVERSE MALFUNCTION Incorrect position of blackout drive/marker light switch. CORRECTIVE ACTION Place blackout drive/marker light switch in OFF position. Check continuity of wires 139 and 135B (Figure 13 (Volume 2, WP 0272)). Repair or replace damaged wires or connectors (Volume 2, WP 0267).

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Electrical Troubleshooting Procedures (Non-Error Code) - Continued MALFUNCTION Circuit breaker F10 tripped. CORRECTIVE ACTION 1. 2. Reset circuit breaker as required. If breaker does not reset, use the wiring diagram to check circuit for short to ground (Figure 14 (Volume 2, WP 0272)). Replace any shorted or grounded harnesses (Volume 2, WP 0267). Replace damaged or faulty circuit breaker (WP 0103).

3.

MALFUNCTION Backup lights and alarm damaged or burned out lamps. CORRECTIVE ACTION 1. 2. 3. Replace burned out lamps (WP 0110). Replace damaged backup lights (WP 0110). Replace damaged backup alarm (WP 0133).

MALFUNCTION Backup lights/alarm wiring harnesses and connectors damaged. CORRECTIVE ACTION Repair or replace damaged harnesses or connectors (Volume 2, WP 0267). MALFUNCTION No voltage (24V) at XK5 pin 1 and 7 with the ignition on and the transmission control lever placed in Reverse. CORRECTIVE ACTION 1. 2. 3. Check continuity of wire A57 (Figure 14 (Volume 2, WP 0272)). Repair or replace damaged wires or connectors (Volume 2, WP 0267). Replace damaged or faulty relay (WP 0103).

MALFUNCTION No voltage (24V) at XK13 pin 4 and 7 with the ignition on and the transmission control lever placed in Reverse. CORRECTIVE ACTION 1. 2. Check continuity of wire A51 (Figure 14 (Volume 2, WP 0272)). Repair or replace damaged wires or connectors (Volume 2, WP 0267).

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Electrical Troubleshooting Procedures (Non-Error Code) - Continued CORRECTIVE ACTION - Continued 3. Replace damaged or faulty relay (WP 0103).

MALFUNCTION No voltage (24V) at XK5 pin 5 with the ignition on while switching transmission control lever between Neutral and Reverse. There should be voltage (24V) when in Neutral and no voltage (OV) when in Reverse. CORRECTIVE ACTION 1. 2. 3. 4. Check continuity of wires A55 and 293 (Figure 14 (Volume 2, WP 0272)). Check continuity of wires 16010 and A17710 (Figure 4 (Volume 2, WP 0272)). Repair or replace damaged wires or connectors (Volume 2, WP 0267). Replace ECU (793).

MALFUNCTION No continuity, using the wiring diagram, of the backup light/alarm wiring harnesses from X14 and X15 to the backup lights and alarm. CORRECTIVE ACTION Repair or replace damaged harnesses or connectors (Volume 2, WP 0267). SYMPTOM BOOM WORK LIGHTS(S) DO NOT OPERATE WHEN SWITCH IS TURNED ON MALFUNCTION Incorrect position of blackout drive/marker light switch. CORRECTIVE ACTION Place blackout drive/marker light switch in OFF position.

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Electrical Troubleshooting Procedures (Non-Error Code) - Continued MALFUNCTION Circuit breaker F12 tripped. CORRECTIVE ACTION 1. 2. 3. Reset circuit breaker as required. If breaker does not reset, use the wiring diagram to check circuit for short to ground (Figure 15 (Volume 2, WP 0272)). Replace any shorted or grounded harnesses (Volume 2, WP 0267). Replace damaged or faulty circuit breaker (WP 0103).

MALFUNCTION Boom work lights damaged or burned out lamps. CORRECTIVE ACTION 1. 2. Replace burned out lamps (WP 0110). Replace damaged lights (WP 0110).

MALFUNCTION Boom work lights wiring harnesses and connectors damaged. CORRECTIVE ACTION Repair or replace damaged harnesses or connectors (Volume 2, WP 0267). MALFUNCTION No voltage (24V) at X7 pin 1 and 3 with the boom work light switch turned on. CORRECTIVE ACTION 1. 2. 3. Check the continuity of wires A73, 73, 71, and A71 (Figure 15 (Volume 2, WP 0272)). Repair or replace damaged wires or connectors (Volume 2, WP 0267). Replace damaged or faulty switch (WP 0094).

MALFUNCTION Inoperative relay 3013 (Volume 2, WP 0267). CORRECTIVE ACTION Replace relay (WP 0103).

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0006

Electrical Troubleshooting Procedures (Non-Error Code) - Continued MALFUNCTION No voltage (24V) at XK11 pin 6, X31 pin 1, X151 pin 1, X157 pin 5, and X169 pin 5 with the boom work light switch turned on. CORRECTIVE ACTION 1. 2. Check continuity of wires A311, 311, A1511, and YE (Figure 15 (Volume 2, WP 0272)). Repair or replace damaged wires or connectors (Volume 2, WP 0267).

MALFUNCTION High resistance between two GY wires at X169 pin 5 and ground. CORRECTIVE ACTION 1. 2. SYMPTOM TOPHANDLER WORK LIGHTS(S) DO NOT OPERATE WHEN SWITCH IS TURNED ON MALFUNCTION Incorrect position of blackout drive/marker light switch. CORRECTIVE ACTION Place blackout drive/marker light switch in OFF position. MALFUNCTION Circuit breakers F17 in cab distribution box and F43, located in the tophandler junction box tripped. CORRECTIVE ACTION 1. 2. Reset circuit breakers as required. If breaker does not reset, use the wiring diagram to check circuit for short to ground (Figure 15 & Figure 16 (Volume 2, WP 0272)). Replace any shorted or grounded harnesses (Volume 2, WP 0267). Replace damaged or faulty circuit breaker (WP 0103). Replace boom work light wiring harness (Volume 2, WP 0267). Repair or replace damaged wires or connectors (Volume 2, WP 0267).

3.

MALFUNCTION Work lights damaged or burned out lamps. CORRECTIVE ACTION 1. Replace burned out lamps (WP 0110).

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Electrical Troubleshooting Procedures (Non-Error Code) - Continued CORRECTIVE ACTION - Continued 2. Replace damaged tophandler work lights (WP 0110).

MALFUNCTION Work lights wiring harnesses and connectors damaged. CORRECTIVE ACTION Repair or replace damaged harnesses or connectors (Volume 2, WP 0267). MALFUNCTION Work light switch inoperative. CORRECTIVE ACTION Enter EXTRA FUNC 5(13)" in the diagnostic menu. Press the tophandler work light switch. Should have a 1" next to WORK LIGHT ATTACH". a. b. If there is a 0", go to No voltage (24V) at X67 pin 8 and 9 with the tophandler work light switch turned on." If there is a 1", go to Inoperative relay 3017."

MALFUNCTION No voltage (24V) at X67 pin 8 and 9 with the tophandler work light switch turned on. CORRECTIVE ACTION 1. 2. 3. Check the continuity of the wires A678, 678, and 679 (Figure 15 (Volume 2, WP 0272)). Repair or replace damaged wires or connectors (Volume 2, WP 0267). Replace damaged or faulty switch (WP 0094).

MALFUNCTION No voltage (24V) at X46 pin 6, X174 pin 11, and ECU (792) pin 102 with the tophandler work light switch turned on. CORRECTIVE ACTION 1. 2. Check continuity of wires A466, 466, and A17411 (Figure 15 (Volume 2, WP 0272)). Repair or replace damaged wires or connectors (Volume 2, WP 0267).

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Electrical Troubleshooting Procedures (Non-Error Code) - Continued MALFUNCTION Inoperative relay 3017 (Volume 2, WP 0267). CORRECTIVE ACTION Replace damaged or faulty relay (WP 0103). MALFUNCTION No voltage at relay 3017 socket pin 30. CORRECTIVE ACTION 1. 2. Check continuity of wires A513 and A1861B (Figure 6 (Volume 2, WP 0272)). Repair or replace damaged wires or connectors (Volume 2, WP 0267).

MALFUNCTION No voltage at 3017 socket pin 86. CORRECTIVE ACTION 1. 2. Check continuity of wire A3018A (Figure 6 (Volume 2, WP 0272)). Repair or replace damaged wires or connectors (Volume 2, WP 0267).

MALFUNCTION No resistance between pin A and B, or C and D on the loose part of X194. (Ensure the tophandler work light lamps are not burned out). CORRECTIVE ACTION 1. 2. Replace X194 harness to tophandler work lights (Volume 2, WP 0267). Repair or replace damaged wires or connectors (Volume 2, WP 0267).

MALFUNCTION No continuity of wires A194A, A194B, A194C, and A194D (Figure 6 (Volume 2, WP 0272)). CORRECTIVE ACTION Repair or replace damaged wires or connectors (Volume 2, WP 0267). MALFUNCTION No voltage at pin 14 of ECU connector 2 with the ignition on. CORRECTIVE ACTION 1. Check continuity of wire A18052B (Figure 6 (Volume 2, WP 0272)).

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Electrical Troubleshooting Procedures (Non-Error Code) - Continued CORRECTIVE ACTION - Continued 2. 3. SYMPTOM INFRARED (IR) WORK LIGHT(S) DO NOT OPERATE WHEN SWITCH IS TURNED ON MALFUNCTION Incorrect position of blackout drive/marker light switch. CORRECTIVE ACTION Place blackout drive/marker light switch in ON position. MALFUNCTION Circuit breaker F2 tripped. CORRECTIVE ACTION 1. 2. Reset circuit breakers as required. If any breaker does not reset, use the wiring diagram to check circuit for short to ground (Figure 13 (Volume 2, WP 0272)). Replace any shorted or grounded harnesses (Volume 2, WP 0267). Replace damaged or faulty circuit breaker (WP 0103). Repair or replace damaged wires or connectors (Volume 2, WP 0267). Replace ECU (791) (WP 0100).

3.

MALFUNCTION IR work lights damaged or burned out lights. (A digital camera can be used to check the operation of IR lights.) CORRECTIVE ACTION 1. 2. Replace burned out lamps (WP 0115). Replace damaged IR light (WP 0115).

MALFUNCTION IR work light wiring harnesses or connectors damaged. CORRECTIVE ACTION Repair or replace damaged harnesses or connectors (Volume 2, WP 0267).

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Electrical Troubleshooting Procedures (Non-Error Code) - Continued MALFUNCTION No voltage (24V) at X6 pin 8 and X7 pin 7 with the blackout drive marker light switch and IR work light switch turned on. CORRECTIVE ACTION 1. 2. 3. Check the continuity of wires A77, 77, 1211, and 68 (Figure 13 (Volume 2, WP 0272)). Repair or replace damaged wires or connectors (Volume 2, WP 0267). Replace damaged or faulty switch (WP 0094).

MALFUNCTION No voltage (24V) at X15 pin 5, X11 pin 5, X31 pin 3, X151 pin 3, X157 pin 7, and X169 pin 7 with the blackout drive marker light switch and IR work light switch turned on. CORRECTIVE ACTION 1. 2. Check continuity of wires A155, A115, A313, 313, A1513, and WH (Figure 13, Figure 14 & Figure 15 (Volume 2, WP 0272)). Repair or replace damaged wires or connectors (Volume 2, WP 0267).

MALFUNCTION No continuity of the IR work light wiring harnesses from X16 pin 7 to left and right boom IR work lights, X15 pin 5 to left rear IR work light, and X11 pin 5 to left front IR work light (Figure 14 & Figure 15 (Volume 2, WP 0272)). CORRECTIVE ACTION Replace damaged or open harness or connectors (Volume 2, WP 0267). SYMPTOM FRONT WINDSHIELD WIPER MOTOR NOT WORKING MALFUNCTION Circuit breaker F6 and F9 tripped. CORRECTIVE ACTION 1. 2. 3. Reset circuit breaker as required. If breaker does not reset, use the wiring diagram to check circuit for short to ground (Figure 10 (Volume 2, WP 0272)). Replace any shorted or grounded harnesses (Volume 2, WP 0267). Replace damaged or faulty circuit breaker (WP 0123).

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Electrical Troubleshooting Procedures (Non-Error Code) - Continued MALFUNCTION Wiper arm binding or damaged. CORRECTIVE ACTION 1. 2. Correct binding wiper arm (Volume 2, WP 0194). Replace damage wiper arm (Volume 2, WP 0194).

MALFUNCTION No voltage (24V) at X20 pin 1, 4, and 5 with the ignition on while operating the front wiper control switch. CORRECTIVE ACTION 1. There should be voltage (24V) at pin 4 for intermittent wiper and at pin 5 for continuous wiper. If no voltage (24V) is found at X20 pin 1, check circuit breaker F9 and continuity of wire A201 (Figure 11 (Volume 2, WP 0272)). If no voltage (24V) is found at X20 pin 4 or 5 while operating the front wiper control switch, check accessory control lever for damage and continuity and check continuity of wires 201, 204, and 205 (Figure 11 (Volume 2, WP 0272)). Replace damaged or faulty accessory control lever (Volume 2, WP 0167). Repair or replace damaged wires or connectors (Volume 2, WP 0267).

2.

3. 4.

MALFUNCTION Defective relay 316. CORRECTIVE ACTION Replace damaged or open harness or connectors (Volume 2, WP 0267). MALFUNCTION No continuity between XK2 pin 9 and terminal 30, XK2 pin 3 and terminal 87, XK2 pin 6 and terminal 87a, XK2 pin 8 and terminal 86, and XK3 pin 5 and terminal 85. CORRECTIVE ACTION Replace damaged or faulty relay board (WP 0103). MALFUNCTION No voltage (24V) at X27 pin 6 and 7 with the ignition on while operating the front wiper control switch to the "CONTINUOUS" position. CORRECTIVE ACTION 1. Check circuit breaker F6 and continuity of wires A276, A66, and A191 (Figure 14 (Volume 2, WP 0272)).

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Electrical Troubleshooting Procedures (Non-Error Code) - Continued CORRECTIVE ACTION - Continued 2. If no voltage (24V) is found at X27 pin 7 while operating the front wiper control switch to the "CONTINUOUS" position, check continuity of wires A23 and A29 (Figure 11 (Volume 2, WP 0272)). Repair or replace damaged wires or connectors (Volume 2, WP 0267).

3.

MALFUNCTION Intermittent relay 321-1 damaged. CORRECTIVE ACTION 1. Disconnect relay plug and check voltage (24) at pin 3 and 5 with the ignition on while operating the front wiper control switch to the "INTERMITTENT" position. If no voltage (24V) is found at 321-1 pin 3 or 5, check continuity of wires A201A, A204, A26, and A278 (Figure 11 (Volume 2, WP 0272)). Replace damaged or faulty relay (WP 0103). Repair or replace damaged wires or connectors (Volume 2, WP 0267).

2. 3.

MALFUNCTION No voltage (24V)at XS4 pin 3 and 4 with the ignition on while operating the front wiper control switch to the "CONTINUOUS" position. CORRECTIVE ACTION 1. 2. 3. 4. SYMPTOM REAR WINDSHIELD WIPER MOTOR NOT WORKING MALFUNCTION Circuit breaker F15 tripped. CORRECTIVE ACTION 1. 2. 3. Reset circuit breaker as required. If breaker does not reset, use the wiring diagram to check circuit for short to ground (Volume 2, WP 0272). Replace any shorted or grounded harnesses (Volume 2, WP 0267). Replace damaged or faulty circuit breaker (WP 0103). Check continuity of wires 276, 277, and 278 (Figure 11 (Volume 2, WP 0272)). Check ground connection at wiper motor. Check continuity of wires 279, A279, and ground connection at 37-1 (Figure 11 (Volume 2, WP 0272)). Repair or replace damaged wires or connectors (Volume 2, WP 0267). Replace damaged or faulty front wiper motor (Volume 2, WP 0194).

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Electrical Troubleshooting Procedures (Non-Error Code) - Continued MALFUNCTION Wiper arm binding or damaged. CORRECTIVE ACTION 1. 2. Correct binding wiper arm (Volume 2, WP 0194). Replace damaged wiper arm (Volume 2, WP 0194).

MALFUNCTION No voltage (24V) at X9 pin 1, 2, and 3 with the ignition on while operating the rear wiper control switch. There should be voltage (24V) at pin 1 (intermittent voltage) and 2 for intermittent wiper. CORRECTIVE ACTION 1. 2. Check circuit breaker F15 and continuity of wires A89 and A89A (Figure 11 (Volume 2, WP 0272)). If no voltage (24V) is found at X9 pin 1 or 2 while operating the rear wiper control switch, check rear wiper switch for damage and continuity and check continuity of wires 91, 92, 93, 94, and A94 (Figure 11 (Volume 2, WP 0272)). Replace damaged or faulty rear wiper switch (WP 0094). Repair or replace damaged wires or connectors (Volume 2, WP 0267).

3. 4.

MALFUNCTION No voltage (24V) at pin 3 and 5 with the ignition on while operating the rear wiper control switch to the "INTERMITTENT" position. CORRECTIVE ACTION 1. 2. 3. Check continuity of wires A91, A92, A93, A138, A136, A246, and A84B (Figure 11 (Volume 2, WP 0272)). Replace damaged or faulty relay (WP 0103). Repair or replace damaged wires or connectors (Volume 2, WP 0267).

MALFUNCTION No voltage (24V) at XS5 pin 2 and 3 with the ignition on while operating the rear wiper control switch to the "CONTINUOUS" position. CORRECTIVE ACTION 1. 2. 3. 4. Check continuity of wires 136, 137, and 138 (Figure 11 (Volume 2, WP 0272)). Check ground connection at wiper motor. Check continuity of wire 135 and ground connection at 37-1 (Figure 11 (Volume 2, WP 0272)). Repair or replace damaged wires or connectors (Volume 2, WP 0267). Replace damaged or faulty rear wiper motor (Volume 2, WP 0194).

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Electrical Troubleshooting Procedures (Non-Error Code) - Continued SYMPTOM ROOF WINDSHIELD WIPER MOTOR NOT WORKING MALFUNCTION Circuit breaker F15 tripped. CORRECTIVE ACTION 1. 2. 3. Reset circuit breaker as required. If breaker does not reset, use the wiring diagram to check circuit for short to ground (Figure 10 (Volume 2, WP 0272)). Replace any shorted or grounded harnesses (Volume 2, WP 0267). Replace damaged or faulty circuit breaker (WP 0103).

MALFUNCTION Wiper arm binding or damaged. CORRECTIVE ACTION 1. 2. Correct binding wiper arm (Volume 2, WP 0194). Replace damage wiper arm (Volume 2, WP 0194).

MALFUNCTION No voltage (24V) at X8 pin 7, 8, and 9 with the ignition on while operating the roof wiper control switch. CORRECTIVE ACTION 1. 2. There should be voltage (24V) at pin 8 and 9, and intermittent voltage at pin 7. Check circuit breaker F15 and continuity of wire A89 (Figure 11 (Volume 2, WP 0272)). If no voltage (24V) is found at X8 pin 7 or 8 while operating the roof wiper control switch, check roof wiper switch for damage and continuity and check continuity of wires 87, 88, and 89 (Figure 11 (Volume 2, WP 0272)). Repair or replace damaged wires or connectors (Volume 2, WP 0267). Replace damaged or faulty roof wiper switch (WP 0094).

3. 4.

MALFUNCTION No voltage (24V) at XS6 pin 2 and 3 with the ignition on while operating the roof wiper control switch. CORRECTIVE ACTION 1. 2. 3. Check continuity of wires A89A, A93, A246, 246, A88, 249, A87, and 244 (Figure 11 (Volume 2, WP 0272)). Check ground connection at wiper motor. Check continuity of wire 241A and ground connection at 37-2 (Figure 11 (Volume 2, WP 0272)). Repair or replace damaged wires or connectors (Figure 11 (Volume 2, WP 0272)).

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Electrical Troubleshooting Procedures (Non-Error Code) - Continued CORRECTIVE ACTION - Continued 4. SYMPTOM WINDSHIELD WASHER NOT WORKING MALFUNCTION Washer reservoir damaged or washer solvent level low. CORRECTIVE ACTION 1. 2. Fill washer reservoir with proper washer solvent (TM 10-3930-675-10). Replace damaged washer reservoir (Volume 2, WP 0195). Replace damaged or faulty rear wiper motor (Volume 2, WP 0194).

MALFUNCTION Washer pump, tubing, fittings, connectors, or wiring damaged. CORRECTIVE ACTION 1. 2. 3. Replace damaged tubing or fittings (Volume 2, WP 0195). Replace damaged washer pump (Volume 2, WP 0195). Repair or replace damaged harnesses or connectors (Volume 2, WP 0195).

MALFUNCTION Circuit breaker F9 tripped. CORRECTIVE ACTION Reset circuit breaker as required. MALFUNCTION No voltage (24V) at X20 pin 1 and 3 with the ignition on and the washer switch depressed. CORRECTIVE ACTION 1. 2. 3. 4. Check circuit breaker F9 and check continuity of wire A201 (Figure 11 (Volume 2, WP 0272)). If no voltage (24V) is found at X20 pin 3, check continuity of wires 201 and 203 (Figure 13 (Volume 2, WP 0272)). Check accessory control lever for damage and continuity (Figure 13 (Volume 2, WP 0272)). Replace damaged or faulty accessory control lever (Volume 2, WP 0167).

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Electrical Troubleshooting Procedures (Non-Error Code) - Continued MALFUNCTION No voltage between the two pins if the harness with the ignition on and the washer switch depressed. CORRECTIVE ACTION 1. 2. Check continuity of wires A203, 131, A135A, and ground connection of wire A132D at 37-1 (Figure 13 (Volume 2, WP 0272)). Repair or replace damaged wires or connector (Volume 2, WP 0267).

MALFUNCTION No resistance of the pump. CORRECTIVE ACTION If there is no resistance or pump fails test, replace washer pump (Volume 2, WP 0195). Resistance should be 3 to 4 Ohms. SYMPTOM CAB INTERIOR LIGHT NOT WORKING MALFUNCTION Incorrect position of blackout drive/marker light switch. CORRECTIVE ACTION Place blackout drive/marker light switch in OFF position. MALFUNCTION Emergency flashers inoperative. CORRECTIVE ACTION 1. 2. Perform troubleshooting procedure Turn Signals or Emergency Flashers Not Working" in this work package. Continue with Step 3.

MALFUNCTION Cab interior light damaged or burned out lamps. CORRECTIVE ACTION 1. 2. Replace burned out lamps (WP 0114). Replace damaged cab interior light (WP 0114).

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Electrical Troubleshooting Procedures (Non-Error Code) - Continued MALFUNCTION No voltage (24V) at cab interior light between the gray and white wires. CORRECTIVE ACTION 1. 2. SYMPTOM 12V UTILITY PLUG NOT WORKING MALFUNCTION Circuit breaker F14 tripped. CORRECTIVE ACTION Replace circuit breaker as required. MALFUNCTION No voltage at the 12V utility plug, CORRECTIVE ACTION 1. With the ignition on, between pins 1 and 4. There should be 12V. Check voltage between pins 2 and 4. There should be 24V. If voltage (24V) is found at pin 2 and none at pin 1, remove the cab electrical distribution box to gain access to the voltage converter. If no voltage (24V) is found at pin 2, check circuit breaker F14 and continuity of wires 108, A108A, 101, 102, and A102 (Figure 13 (Volume 2, WP 0272)). Repair or replace damaged wires or connectors (Volume 2, WP 0267). If no voltage (24V) is found, check continuity of wires 248, A69, 241B, and connection at 37-2 (Figure 13 (Volume 2, WP 0272)). Check continuity of light switch. If the switch is damaged or faulty, replace cab interior light (WP 0114).

2. 3.

MALFUNCTION The 5 amp fuse on the voltage converter blown. CORRECTIVE ACTION Replace the 5 amp fuse if blown. MALFUNCTION No input voltage (24V) of the voltage converter to one of the two middle pins on the converter. CORRECTIVE ACTION 1. With ignition on if no input voltage (24V) is found, check circuit breaker F14 and check continuity of wire A108 (Figure 13 (Volume 2, WP 0272)).

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Electrical Troubleshooting Procedures (Non-Error Code) - Continued CORRECTIVE ACTION - Continued 2. 3. 4. SYMPTOM BLOWER MOTOR NOT WORKING MALFUNCTION Circuit breaker F11 tripped. (For rear blower troubleshooting, go to Binding blower wheel or damage to the motor or wiring.") CORRECTIVE ACTION 1. 2. 3. Reset circuit breaker as required. If breaker does not reset, use the wiring diagram to check circuit for short to ground (Figure 12 (Volume 2, WP 0272)). Replace any shorted or grounded harnesses (Volume 2, WP 0267). Replace damaged or faulty circuit breaker (WP 0103). Reinstall jumper wire A101B and check wires A101A and A101 continuity/ground connection at 37-5 (Figure 13 (Volume 2, WP 0272)). With the ignition on, check the output voltage (12V) of the converter to one of the two middle pins on the converter. If no output voltage from converter is found, replace voltage converter (WP 0103).

MALFUNCTION Blower damaged or blower wheel binding (Volume 2, WP 0198). CORRECTIVE ACTION Replace damaged or binding blower motor/assembly (Volume 2, WP 0198). MALFUNCTION Blower assembly wiring and connectors damaged (Volume 2, WP 0198). CORRECTIVE ACTION Repair or replace damaged harnesses or connectors (Volume 2, WP 0267). MALFUNCTION No voltage (24V) at X9 pin 6 and 9 with the ignition on while operating the fan control switch. CORRECTIVE ACTION 1. 2. There should be varied voltage (14 to 24V) at pin 6. If no voltage (24V) is found at X9 pin 9, check circuit breaker F11 and continuity of wires A99 and 99 (Figure 12 (Volume 2, WP 0272)). If no voltage (14 to 24V) is found at X9 pin 6 at any on speed, remove fan control switch and check for continuity (WP 0094).

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Electrical Troubleshooting Procedures (Non-Error Code) - Continued CORRECTIVE ACTION - Continued 3. 4. 5. Replace damaged or faulty switch (Volume 2, WP 0272). If switch is good, check the continuity of wires 96, 97, 98, A96, A97, and A98 (Volume 2, WP 0267). Repair or replace damaged wires or connectors (Volume 2, WP 0267).

MALFUNCTION No voltage (24V) at X657 pin 2, 3, and 4 with the ignition on while operating the fan control switch. CORRECTIVE ACTION 1. 2. There should be voltage (24V) at pin 2 for LOW, pin 4 for MED, and pin 3 for HIGH. If no voltage is found, check continuity of wires, 271, 272, and 273 (Figure 12 (Volume 2, WP 0272)). Repair or replace damaged wires or connectors (Volume 2, WP 0267).

MALFUNCTION No ground connection for the white wire at X657 pin 1 and at 37-10. CORRECTIVE ACTION Repair or replace damaged wires or connectors (Volume 2, WP 0267). MALFUNCTION No voltage between the two blower motor connectors with the ignition on while operating the fan control switch to HIGH speed. CORRECTIVE ACTION 1. 2. Replace the internal blower assembly harness (Volume 2, WP 0198). Replace blower motor/assembly (Volume 2, WP 0198).

MALFUNCTION Binding blower wheel or damage to the motor or wiring (Volume 2, WP 0198). CORRECTIVE ACTION 1. 2. Replace damaged or binding blower motor/assembly (Volume 2, WP 0198). Repair or replace damaged wires or connectors (Volume 2, WP 0267).

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Electrical Troubleshooting Procedures (Non-Error Code) - Continued MALFUNCTION No voltage (24V) at X69 pin 1 with the ignition on while operating the fan control switch. CORRECTIVE ACTION There should be varied voltage (14 to 24V). If no voltage is found and front blower operates properly, check continuity of wires A691 and A692 (Figure 10 (Volume 2, WP 0272)). MALFUNCTION No voltage (24V) X657-1 with the ignition on while operating the fan control switch to HIGH speed. CORRECTIVE ACTION 1. 2. SYMPTOM HEATER/DEFROSTER PRODUCING LOW OR NO HEAT MALFUNCTION Incorrect operating temperature of engine. CORRECTIVE ACTION 1. 2. Perform proper PMCS for coolant system (TM 10-3930- 675-10). Warm engine to proper operating temperature (TM 10-3930-675-10). Check continuity of wires BU and BK (Figure 10 (Volume 2, WP 0272)). If voltage is found, replace rear blower motor/assembly (Volume 2, WP 0198).

MALFUNCTION Heater hoses between the cab and chassis kinked. CORRECTIVE ACTION 1. 2. Straighten any kinked hoses (Volume 2, WP 0198). Replace any damaged hoses or kinked hose that will not straighten (Volume 2, WP 0196).

MALFUNCTION Inoperative blower. CORRECTIVE ACTION If blower not functioning, perform troubleshooting procedure for Blower Motor Not Working" in this work package.

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Electrical Troubleshooting Procedures (Non-Error Code) - Continued MALFUNCTION Inoperative heater temperature control switch and heater/defroster selection switch operation. CORRECTIVE ACTION 1. 2. Replace damaged or binding heater temperature control switch (WP 0094). Replace damaged or binding heater/defroster selection switch (WP 0094).

MALFUNCTION Heater control valve and cable inoperative. CORRECTIVE ACTION 1. 2. 3. Replace bent or kinked control cable (WP 0094) and (Volume 2, WP 0198). Replace damaged, leaking, or non-operational heater control valve (Volume 2, WP 0196). Correct any binding of air flow door and cable.

MALFUNCTION Inoperative air flow door while operating the heater/defrost selection switch. CORRECTIVE ACTION Replace damaged or binding heater/defrost selection switch. MALFUNCTION Air conditioning ducts damaged. CORRECTIVE ACTION Repair or replace any damaged or separated ducts. MALFUNCTION Restricted airflow through heater core. CORRECTIVE ACTION If air flow is very low through heater core, perform A/C system maintenance (Volume 2, WP 0248). SYMPTOM A/C SYSTEM NOT COOLING PROPERLY

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Electrical Troubleshooting Procedures (Non-Error Code) - Continued MALFUNCTION Blower inoperative. CORRECTIVE ACTION If blower not functioning, perform troubleshooting procedure for Blower Motor Not Working" in this work package. MALFUNCTION Poor condition of the A/C compressor belts. CORRECTIVE ACTION Replace and/or adjust belts as required (Volume 2, WP 0251). MALFUNCTION Improper A/C operation. CORRECTIVE ACTION 1. 2. 3. 4. If compressor operates and condenser fans are on, go to Step 4. If compressor does not operate, go to malfunction AA. If condenser fans do not operate, go to malfunction BB. Run the A/C system for about 15 minutes to stabilize. Feel the air coming from the condenser fans; it should be warmer than the ambient temperature. Feel the temperature of the larger pipe connected to the compressor; it should be cool or cold and possibly sweating. a. b. If condenser air is warm and the compressor pipe is cool/ cold, check if the heater control valve is fully closed and the air is properly flowing through the ducts (Volume 2, WP 0251). If condenser air is not warm and the compressor pipe is not cool/cold, perform A/C system maintenance (Volume 2, WP 0248).

MALFUNCTION Malfunction AA: No voltage (24V) at X27 pin 4 and 5 while operating the A/C system to maximum cool. CORRECTIVE ACTION 1. 2. 3. At X27 pin 4, remove the A/C control switch and check continuity of wires 99A, 95, and A95 (Figure 12 (Volume 2, WP 0272)). At X27 pin 5, remove A/C temperature control switch and check continuity of wires 274 and 275 (Figure 12 (Volume 2, WP 0272)). Replace damaged or faulty switch (WP 0094).

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Electrical Troubleshooting Procedures (Non-Error Code) - Continued MALFUNCTION No voltage (24V) at X17 pin 8 while operating the A/C system to maximum cool. CORRECTIVE ACTION 1. 2. At X17 pin 8, check continuity of wires A327, 327, 328, and A178 (Figure 12 (Volume 2, WP 0272)). At X17 pin 8 and all wires are functioning properly, remove the cover of the condenser and unplug the pressure switch. Check continuity of the pressure switch between wires RD/WH and BK/WH (X810 pins 3 and 4). If no continuity is found at pressure switch, perform A/C system maintenance (Volume 2, WP 0248) to check the refrigerant charge of the system.

3.

MALFUNCTION No voltage (24V) at compressor clutch while operating the A/C system to maximum cool. CORRECTIVE ACTION 1. 2. 3. Check continuity of wire 178 (Figure 12 (Volume 2, WP 0272)). If voltage (24V) is found, check the resistance of the compressor clutch to ground. Resistance should be 12 to 16 Ohms. If resistance of compressor clutch is not as specified, replace compressor (Volume 2, WP 0250).

MALFUNCTION Malfunction BB: Circuit breaker F1 tripped. CORRECTIVE ACTION 1. 2. 3. 4. 5. 6. Reset circuit breaker as required. Unplug X810 and check voltage (24V) at X810 pins 1 and 2 while operating the A/C system. If no voltage (24V) is found at X810 pin 2, check continuity of wires A95A and 322 (Figure 12 (Volume 2, WP 0272)). If no voltage (24V) is found at X810 pin 3, check circuit breaker F1 and continuity of wires A323 and 323 (Figure 12 (Volume 2, WP 0272)). Check continuity of wires (X810 pin 6) 329, A329, and ground connection at 37-5 (Figure 12 (Volume 2, WP 0272)). Repair or replace damaged wires or connectors (Volume 2, WP 0267).

MALFUNCTION Fans, Relay or wiring damage. CORRECTIVE ACTION 1. Replace damaged or faulty relay (WP 0103).

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Electrical Troubleshooting Procedures (Non-Error Code) - Continued CORRECTIVE ACTION - Continued 2. 3. Replace damaged fans (Volume 2, WP 0254). Repair or replace damaged wires or connectors (Volume 2, WP 0267).

MALFUNCTION Resistance out of range for fans and resistors. CORRECTIVE ACTION Resistance should be 2 Ohms. If resistance is not as specified replace faulty fan(s) or resistor(s) (Volume 2, WP 0254). SYMPTOM FUEL GAUGE NOT WORKING PROPERLY MALFUNCTION Circuit breaker F7 tripped. CORRECTIVE ACTION Reset circuit breaker as required. MALFUNCTION Fuel level sending unit damaged. CORRECTIVE ACTION Replace fuel level sending unit. MALFUNCTION Fuel gauge damaged. Remove the dash panel to access the fuel gauge. CORRECTIVE ACTION Replace damaged fuel gauge (WP 0094). MALFUNCTION Wire connector damaged (WP 0094). CORRECTIVE ACTION Repair or replace damaged wires or connectors (Volume 2, WP 0267).

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Electrical Troubleshooting Procedures (Non-Error Code) - Continued MALFUNCTION No voltage (24V) at the + terminal of the gauge. CORRECTIVE ACTION Check circuit breaker F7 and continuity of wires A211, A104, and 104 (Figure 10 (Volume 2, WP 0272)). MALFUNCTION Float for damaged, sticking, or waterlog." CORRECTIVE ACTION Replace damaged fuel level sending unit (WP 0132). MALFUNCTION Incorrect resistance of fuel level sending unit. CORRECTIVE ACTION 1. 2. 3. 4. Float at bottom = 110 Ohms, float in middle = approx. 50 Ohms, and float at top = <1 Ohm. If resistance is not as specified, replace faulty fuel level sending unit (WP 0132). If resistance checks good, check continuity of wires 258, 259, A105, 105, and ground wire A132D at the 37-1 ground connection (Figure 10 (Volume 2, WP 0272)). Repair or replace damaged wires or connectors (Volume 2, WP 0267).

MALFUNCTION Improper operation of the gauge. CORRECTIVE ACTION 1. 2. If gauge does not react to float movement, replace faulty gauge (WP 0094). If gauge does react but does not match with the float level, try adjusting the small adjustment screw on gauge to empty" with the float at the bottom. Retest float/gauge reactions.

SYMPTOM DRIVERS ECS DISPLAY SCREEN WILL NOT DISPLAY MALFUNCTION Circuit breaker F31 tripped. CORRECTIVE ACTION Reset circuit breaker as required.

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Electrical Troubleshooting Procedures (Non-Error Code) - Continued MALFUNCTION No voltage (24V) at X150 pin 3 with the ignition on. CORRECTIVE ACTION 1. 2. 3. Check circuit breaker F31 and continuity of wires A303 and 303 (Figure 8 (Volume 2, WP 0272)). Repair or replace damaged wires or connectors (Volume 2, WP 0267). Replace damaged or faulty circuit breaker (WP 0103).

MALFUNCTION No voltage (24V) at X152 pin 3 with the ignition on. CORRECTIVE ACTION 1. 2. Check continuity of wire A1503B (Figure 1 (Volume 2, WP 0272)). Repair or replace damaged wires or connectors (WP 0103).

MALFUNCTION No voltage (24V) at X795 pins 7 and 8 with the ignition on. CORRECTIVE ACTION 1. 2. 3. SYMPTOM After Key On" FUNCTIONS NOT WORKING (NO CRANK, DISPLAY, ETC.). MALFUNCTION With the battery master switch turned on and the ignition turned off, turn signals/emergency flashers and cab interior light inoperative. CORRECTIVE ACTION 1. 2. If all of these functions work properly, go to malfunction DD. If none of these functions work properly, go to malfunction CC. Check continuity of wires 1523A and 1523B (Figure 1 (Volume 2, WP 0272)). Repair or replace damaged wires or connectors (Volume 2, WP 0267). If voltage (24V) is found, replace the ECS display screen (WP 0096).

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Electrical Troubleshooting Procedures (Non-Error Code) - Continued MALFUNCTION Malfunction CC: No voltage (24V) at X80 all pins. CORRECTIVE ACTION 1. 2. 3. Check circuit breakers F50-1 and F50-2 located at upper left rear of engine, and continuity of wires 801 and 803 (Figure 8 (Volume 2, WP 0272)). Repair or replace damaged wires or connectors (Volume 2, WP 0267). Replace damaged or faulty circuit breaker (WP 0103).

MALFUNCTION No voltage (24V) at batteries, master battery switch, or starter solenoid on the starter (Figure 8 (Volume 2, WP 0272)). CORRECTIVE ACTION 1. 2. 3. Service batteries (WP 0128). Repair or replace damaged or faulty battery cables (WP 0129). Replace damaged or faulty master battery switch (WP 0129).

MALFUNCTION Malfunction DD: No voltage (24V) at X8 pins 3 and 4 with the ignition on. CORRECTIVE ACTION 1. 2. 3. 4. If no voltage (24V) is found at X8 pin 3, check circuit breaker F2 and continuity of wire A83 (Figure 8 (Volume 2, WP 0272)). If no voltage (24V) is found at X8 pin 4, check ignition switch for damage and continuity and check continuity of wire 84 (Figure 8 (Volume 2, WP 0272)). Replace damaged or faulty ignition switch (WP 0094). Repair or replace damaged wires or connectors (Volume 2, WP 0267).

MALFUNCTION No voltage (24V) at relay 315 terminal 30 and 87 (two brass terminals) and terminal 86 (white plug; gray wires) with ignition on. CORRECTIVE ACTION 1. 2. 3. 4. At 315 terminal 30, check continuity of wire A804 (Figure 8 (Volume 2, WP 0272)). At 315 terminal 86, check continuity of wire A84 (Figure 8 (Volume 2, WP 0272)). Replace damaged or faulty relay (WP 0103). Repair or replace damaged or loose wires or connectors (Volume 2, WP 0267).

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Electrical Troubleshooting Procedures (Non-Error Code) - Continued MALFUNCTION No continuity of wire A84C and its ground connection at 37-1 (Figure 8 (Volume 2, WP 0272)). CORRECTIVE ACTION Repair or replace damaged or loose wires or connectors (Volume 2, WP 0267). MALFUNCTION Damaged wiring. CORRECTIVE ACTION 1. 2. SYMPTOM PROXIMITY SWITCHES - TOPHANDLER AND CAB MALFUNCTION Inoperative proximity switches: CORRECTIVE ACTION Repair or replace damaged or loose wires or connectors (Volume 2, WP 0267). Check jumper connections between circuit breakers (Figure 8 (Volume 2, WP 0272)).

NOTE
All proximity switches on the RTCH operate and are connected the same way. Many non-ERROR CODE problems may be caused by a faulty proximity switch or the proximity switch signal not reaching its destination. "DIAG ATTACHMENT 3(16)", "DIAG ATTACHMENT 4(16)", "DIAG ATTACHMENT 5(16)", and "DIAG EXTRA FUNCT 8(13)" screens can be used to verify the signal inputs into the ECU (790) or (791). All Proximity Switches - General operation. Each proximity switch has three wires: - Brown = voltage (24V) input - Blue = ground - Black = signal; voltage (24V) output when activated Activation = metal within 5 mm of end of proximity switch. Indicator = small Light Emitting Diode (LED) comes on when activated. Voltage (24V) to proximity switches comes from circuit breaker F42 (2) in the tophandler junction box. The main grounding point is 37-54 (Figure 6 (Volume 2, WP 0272)). 1. 2. 3. Reset circuit breaker as required. Replace damaged or faulty circuit breaker (WP 0103). Repair or replace damaged wires or connectors (Volume 2, WP 0267).

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Electrical Troubleshooting Procedures (Non-Error Code) - Continued MALFUNCTION No voltage (24V) at X182 between pins 4 and 5 (Figure 6 (Volume 2, WP 0272)) with the ignition on. CORRECTIVE ACTION 1. 2. 3. Check continuity of wires A181A, A181B, and wires 4 and 5 in the X181 to X182 cable (Figure 6 (Volume 2, WP 0272)). Repair or replace damaged wires or connectors (Volume 2, WP 0267). Replace X181 to X182 cable (Volume 2, WP 0267).

MALFUNCTION No voltage (24V) at X183 between pins 3 and 4 (Figure 6 (Volume 2, WP 0272)) with the ignition on. CORRECTIVE ACTION 1. 2. 3. Check continuity of wires 3 and 4 in the X182 to X183 cable (Figure 6 (Volume 2, WP 0272)). Repair or replace damaged wires or connectors (Volume 2, WP 0267). Replace X182 to X183 cable, electrical general maintenance (Volume 2, WP 0267).

MALFUNCTION No voltage (24V) at X184 between pins 3 and 4 (Figure 6 (Volume 2, WP 0272)) with the ignition on. CORRECTIVE ACTION 1. 2. 3. Check continuity of wires 3 and 4 in the X182 to X184 cable (Figure 6 (Volume 2, WP 0272)). Repair or replace damaged wires or connectors (Volume 2, WP 0267). Replace X182 to X183 cable, electrical general maintenance (Volume 2, WP 0267).

MALFUNCTION Indicator LED on the switch inoperative. CORRECTIVE ACTION

NOTE
The 7225-1 proximity switch operation can be quickly tested by turning on the tophandler work lights and rotating the tophandler clockwise (CW) toward the longitudinal position. 7225-1, when deactivated, turns off the tophandler work lights beyond 40 degrees of CW rotation. 1. 2. If no LED indicator when activated, check voltage and ground inputs and adjustment first. Replace proximity switch (WP 0104).

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Electrical Troubleshooting Procedures (Non-Error Code) - Continued MALFUNCTION No voltage at ECU (791) connector 1 at pins 30 through 40 with ignition on. CORRECTIVE ACTION 1. 2. 3. 4. 5. Check continuity of wires A181C through A181K (Figure 6 (Volume 2, WP 0272)) and A194G for RT 240V1R, RT 240V2 and RT 240V3. Check continuity of specific wire in X181 to X182 cable (Figure 6 (Volume 2, WP 0272)). Check continuity of specific wire in X182 to X183 cable or X182 to X184 cable (Figure 6 (Volume 2, WP 0272)). Repair or replace damaged wires or connectors (Volume 2, WP 0267). Replace X181 to X182 cable, or X183 cable, or X182 to X184 cable or X194 cable (Volume 2, WP 0267).

MALFUNCTION Circuit breaker F29 tripped. CORRECTIVE ACTION 1. 2. 3. Reset circuit breaker as required. Replace damaged or faulty circuit breaker (WP 0103). Repair or replace damaged wires or connectors (Volume 2, WP 0267).

MALFUNCTION No voltage (24V) at X195 between pins 7 and 9 (Figure 7 (Volume 2, WP 0272)) with the ignition on. CORRECTIVE ACTION 1. Check continuity of wires A473, 473, A1743B, A1743C, and A1957A (WP 0048). For RT 240V1R, RT 240V2 and RT 240V3, check wires A475, 475, A174B1A, A174B1B, and A1957A (WP 0048). Repair or replace damaged wires or connectors (Volume 2, WP 0267).

2.

MALFUNCTION No voltage (24V) at X198 between pins 1 and 3 (Figure 7 (Volume 2, WP 0272)) with the ignition on. CORRECTIVE ACTION 1. 2. Check continuity of wires GY and RD in the X195 to X198 cable (Figure 7 (Volume 2, WP 0272)). Replace X195 to X198 cable (Volume 2, WP 0267).

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Electrical Troubleshooting Procedures (Non-Error Code) - Continued MALFUNCTION No voltage (24V) between X195 pin 5 and 7 (WP 0048). Check LED indicator on the switch. CORRECTIVE ACTION 1. 2. 3. Check continuity of wire OR in the X195 to X198 cable (WP 0048). If no LED indicator when activated, replace proximity switch (WP 0105). Replace X195 to X198 cable (Volume 2, WP 0267).

MALFUNCTION No voltage (24V) at X175 between pins 1 and 3 (WP 0048) with the ignition on. CORRECTIVE ACTION 1. 2. Check continuity of wires A1743D, A1957B, and for RT 240V1R, RT 240V2 and RT 240V3, wire A174B1C (Figure 7 (Volume 2, WP 0272)). Repair or replace damaged wires or connectors (Volume 2, WP 0267).

MALFUNCTION No voltage (24V) between X175 pin 2 and 3 (Figure 7 (Volume 2, WP 0272)). Check LED indicator. CORRECTIVE ACTION Replace proximity switch (WP 0105). SYMPTOM NORMAL FUNCTIONS OPERATE IN BLACKOUT MODE MALFUNCTION Inoperative horn operation in blackout mode. CORRECTIVE ACTION 1. 2. Remove relay 3016 and test (Volume 2, WP 0267). Replace damaged or faulty relay (WP 0103).

MALFUNCTION No backup lights/alarm in blackout mode. CORRECTIVE ACTION 1. 2. Remove relay 3011 and test (Volume 2, WP 0267). Replace damaged or faulty relay (WP 0103).

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Electrical Troubleshooting Procedures (Non-Error Code) - Continued MALFUNCTION No boom work light operation in blackout mode. CORRECTIVE ACTION 1. 2. Remove relay 3013 and test (Volume 2, WP 0267). Replace damaged or faulty relay (WP 0103).

MALFUNCTION No stoplight operation in blackout mode. CORRECTIVE ACTION 1. 2. Remove relay 3010 and test (Volume 2, WP 0267). Replace damaged or faulty relay (WP 0103).

MALFUNCTION Seat buzzer in blackout mode inoperative. CORRECTIVE ACTION 1. 2. SYMPTOM MULTIPLE BOOM OR TOPHANDLER FUNCTIONS NOT WORKING (MULTIPLE ERROR CODES) MALFUNCTION Check for emergency stop in engaged position. (Multiple ERROR CODES Will display if the emergency stop button is engaged during crank and start.). CORRECTIVE ACTION Disengage emergency stop button (ERROR CODES 121 and 201 will normally be one of the ERROR CODES displayed). MALFUNCTION No boom functions, hydraulic pumps engaged when cranking (slow or hard crank), cooling fan at full speed. Multiple ERROR CODES. CORRECTIVE ACTION Erratic voltage (24V) at X159 pin 1 with the ignition on. a. If voltage is 6V or less, unplug X158, turn the ignition off, then back on after 3 minutes. Recheck voltage. Remove relay 3016 and test (Volume 2, WP 0267). Replace damaged or faulty relay (WP 0103).

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Electrical Troubleshooting Procedures (Non-Error Code) - Continued CORRECTIVE ACTION - Continued b. c. d. e. If the voltage (24V) returns to X159 pin 1, check continuity of each pin of the loose part of X158 to ground (Figure 2 (Volume 2, WP 0272)). If the voltage (24V) does not return, unplug X159, turn the ignition off, then back on after 3 minutes. Recheck voltage. If the voltage (24V) returns to X159 pin 1, check continuity of each pin 1 and 2 of the loose part of X159 to ground (Figure 2 (Volume 2, WP 0272)). If continuity to ground found at any pin(s), follow the circuit of the pin/wire to the component it goes to. Unplug the component and recheck for continuity to ground. Replace grounded harness (Figure 2 (Volume 2, WP 0272)).

MALFUNCTION No sideshift, no 20/40 spread, and no twistlock operation. Multiple ERROR CODES. CORRECTIVE ACTION Erratic Voltage (24) at X180 pin 15 with the ignition on. a. b. c. d. e. lf voltage is 6V or less, unplug X188, turn the ignition off, then back on after 3 minutes. Recheck voltage. If the voltage (24V) returns to X180 pin 15, check continuity of each pin J, K, L, M, N, and P of the loose part of X188 to ground (Figure 6 (Volume 2, WP 0272)). If the voltage (24V) does not return to X189, turn the ignition off, then back on, after 3 minutes. Check voltage. If the voltage (24V) returns to X180 pin 15, check continuity of each pin A, B, C, D, J, K, L, M, N, and P of the loose part of X189 to ground (Figure 6 (Volume 2, WP 0272)). If continuity to ground is found at any pin(s), follow the circuit of the pin/wire to the component it goes to. Unplug the component and recheck for continuity to ground. Replace grounded harness (Figure 6 (Volume 2, WP 0272)). If no trouble found, go to No voltage at ECU (791) connectors 2 and 3 between pins 1 and 9 of each connector with the ignition on."

f.

MALFUNCTION No rotate, no tilt, no oscillate, and no twistlock lights on boom. Multiple ERROR CODES. CORRECTIVE ACTION Erratic Voltage (24) at X180 pin 13 with the ignition on. a. b. c. lf voltage is 6V or less, unplug X188, turn the ignition off, then back on after 3 minutes. Recheck voltage. If the voltage (24V) returns to X180 pin 13, check continuity of each pin A, B, C, D, E, F, G, and H of the loose part of X188 to ground (Figure 6 (Volume 2, WP 0272)). lf voltage (24V) does not return, unplug X189, turn the ignition off, then back on after 3 minutes. Recheck voltage.

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Electrical Troubleshooting Procedures (Non-Error Code) - Continued CORRECTIVE ACTION - Continued d. lf continuity to ground is found at any pin(s), follow the circuit of the pin/wire to the component it goes to. Unplug the component and recheck for continuity to ground. Replace grounded harness (Figure 6 (Volume 2, WP 0272)). If no trouble found, go to No voltage at ECU (791) connectors 2 and 3 between pins 1 and 9 of each connector with the ignition on."

e.

MALFUNCTION No sideshift, no 20/40 spread, no rotate, no tilt, no oscillate, no twistlock operation, no twistlock lights on boom, multiple ERROR CODES. CORRECTIVE ACTION No Voltage (24V) at 3009-3 relay socket pins 30 and 86 (Figure 6 (Volume 2, WP 0272)) with the ignition on. a. b. c. d. e. f. Replace damaged or faulty 3009-3 relay (WP 0103). Check circuit breaker F41 (1) and continuity of wires A51J, A51B, and A51D (Figure 6 (Volume 2, WP 0272)). Check operation of relay 315-1 (Figure 6 (Volume 2, WP 0272)), replace damaged or faulty 315-1 relay (WP 0103). If no voltage (24V) is found at 3009-3 pin 86, check continuity of wire A1803C (Figure 6 (Volume 2, WP 0272)). Repair or replace damaged wires or connectors (Volume 2, WP 0267). If no trouble found, go to No voltage at ECU (791) connectors 2 and 3 between pins 1 and 9 of each connector with the ignition on."

MALFUNCTION No voltage at ECU (791) connectors 2 and 3 between pins 1 and 9 of each connector (Figure 6 (Volume 2, WP 0272)) with the ignition on. CORRECTIVE ACTION 1. 2. 3. SYMPTOM FUNCTIONS(S) WORK UNCONTROLLED Check continuity of wires A511, A51H, 791I, and 7912 (Figure 6 (Volume 2, WP 0272)). Repair or replace damaged wires or connectors (Volume 2, WP 0267). Replace ECU (791) (WP 0100).

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Electrical Troubleshooting Procedures (Non-Error Code) - Continued MALFUNCTION Test for electrical or hydraulic fault. Start the engine (TM 10-3930-675-10) and engage the emergency stop button. lf the uncontrolled function stops, its electrical. If the function does not stop, its hydraulic. CORRECTIVE ACTION Disengage the emergency stop button after test. MALFUNCTION Boom functions. Top handler functions. (An uncontrolled function is usually caused by a short to ground or a stuck hydraulic solenoid). CORRECTIVE ACTION 1. Enter DIAG SERVO 5(13)" in the diagnostic menu. The voltage should be 5V. a. If voltage is not 5V: (1) (2) b. Check joystick. Enter DIAG SERVO 9(13)" and DIAG SERVO 10(13)" in the diagnostic menu. The INPUT and OUTPUT should be <5mA With no joystick input. lf mA values > 51mA appear without operating the joystick, replace the joystick (WP 0101).

If voltage is 5V: (1) (2) No continuity of the pins of the harness to ground for the affected function solenoid (Figure 2 (Volume 2, WP 0272)). Replace grounded harness (Figure 2 (Volume 2, WP 0272)).

2.

Check boom functions. Unplug the affected function hydraulic solenoid and start engine. a. b. If function still works, shut down engine and remove the affected solenoid. Check for debris or broken O-rings. Replace servo control valve (Volume 2, WP 0207). Replace main control valve (Volume 2, WP 0214).

3.

Test voltage. Enter DIAG SERVO 6(13)" in the diagnostic menu. The Voltage should be 5V. a. lf Voltage is not 5V: (1) (2) b. Check amperage. Enter DIAG SERVO 12(13) and DIAG SERVO 13(13)" in the diagnostic menu. The INPUT and OUTPUT should be <5mA With no joystick input. If mA values >5mA appear Without operating the joystick, replace joystick (WP 0101).

lf Voltage is 5V: (1) Test for button stuck on condition. Enter DIAG SERVO screens 2 (13)" and DIAG SERVO 3 (13)" in the diagnostic menu. Each Value should be 0" With no joystick buttons pressed. If a button appears to be stuck on, replace joystick (WP 0101).

(2) 4.

No continuity of the pins of the harness to ground for the affected function (Figure 6 (Volume 2, WP 0272)). Replace grounded harness (WP 0101).

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Electrical Troubleshooting Procedures (Non-Error Code) - Continued CORRECTIVE ACTION - Continued 5. Unplug the affected function hydraulic solenoid and start engine. If function still Works, shut down engine and remove the affected solenoid. Check for debris or broken O-rings. Replace faulty solenoid (Volume 2, WP 0217). Brake System Troubleshooting Procedures (Non-Error Code). SYMPTOM BRAKING IS POOR OR NONEXISTENT MALFUNCTION Accumulator shutoff valves are in CLOSED position. CORRECTIVE ACTION Close shutoff valves as required (Volume 2, WP 0204). MALFUNCTION Brake pedals are damaged or obstructed. CORRECTIVE ACTION 1. 2. Remove any obstructions. Repair or replace damaged brake pedal (Volume 2, WP 0160).

MALFUNCTION Hydraulic brake lines and hoses damaged or signs of leakage. CORRECTIVE ACTION 1. 2. Tighten loose connections. Repair or replace damaged or leaking lines and hoses (Volume 2, WP 0157).

MALFUNCTION Incorrect brake charging valve opening pressure for brake system circuits 1 and 2, test points 1 and 2 (Volume 2, WP 0245). CORRECTIVE ACTION 1. 2. 3. 4. If accumulator pre-charge nitrogen pressures are not normal, service accumulators (Volume 2, WP 0154). Replace service brake control valve (Volume 2, WP 0153). lf operating pressure is low, replace boom and brake system pump (Volume 2, WP 0205). Test operating pressures for brake system circuits 1 and 2, test points 4

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Brake System Troubleshooting Procedures (Non-Error Code) - Continued. CORRECTIVE ACTION - Continued and 5 (Volume 2, WP 0245). 5. SYMPTOM PARKING BRAKE WILL NOT RELEASE MALFUNCTION Accumulator shutoff valves are in CLOSED position. CORRECTIVE ACTION Close shutoff valve as required (Volume 2, WP 0204). MALFUNCTION Parking brake control lever damaged or obstructed. CORRECTIVE ACTION 1. 2. Remove any obstructions. Replace damaged parking brake control valve (Volume 2, WP 0151). Replace service brake control valve (Volume 2, WP 0153).

MALFUNCTION Hydraulic brake hoses and lines for damaged or signs of leakage. CORRECTIVE ACTION 1. 2. 3. Tighten loose connections. Replace damaged or leaking lines and hoses (Volume 2, WP 0152). Test brake charging valve opening pressure for brake system circuit 2, test point 4 (Volume 2, WP 0245). a. b. Check parking brake calipers for parking brake release if pressure check is normal. Check pad adjustment (Volume 2, WP 0150). If parking brakes do not release at the calipers, replace the parking brake control valve (Volume 2, WP 0151).

MALFUNCTION Transmission will not engage. CORRECTIVE ACTION If transmission will engage but brake seems to be engaged, replace the parking brake flow control valve located next to the brake system accumulator shutoff valves.

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Brake System Troubleshooting Procedures (Non-Error Code) - Continued. SYMPTOM PARKING BRAKE WILL NOT ENGAGE MALFUNCTION Front and rear parking brake assemblies and brake pads worn or damaged. CORRECTIVE ACTION 1. 2. Replace Worn parking brake pads (Volume 2, WP 0150). Notify Direct Support (DS) maintenance if parking brake assembly is damaged.

MALFUNCTION Parking brake pads not properly adjusted. CORRECTIVE ACTION Adjust parking brake pad clearance (Volume 2, WP 0150). MALFUNCTION Parking brake control lever obstructed or damaged. CORRECTIVE ACTION 1. 2. Remove any obstructions. Replace damaged parking brake control lever (Volume 2, WP 0151).

MALFUNCTION Hydraulic brake hoses and lines damaged or signs of leakage. CORRECTIVE ACTION 1. 2. Tighten loose connections. Replace damaged or leaking lines and hoses (Volume 2, WP 0152).

Steering System Troubleshooting Procedures (Non-Error Code). SYMPTOM STEERING CONTROL IS POOR OR NONEXISTENT

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Steering System Troubleshooting Procedures (Non-Error Code) - Continued. MALFUNCTION Has active steering error code(s). CORRECTIVE ACTION Perform troubleshooting for active error code(s) (WP 0004). MALFUNCTION Dump valve open. CORRECTIVE ACTION Close steering system dump valve (Volume 2, WP 0204). MALFUNCTION Steering system components, lines, hoses, and cylinders for damage, leaks, or obstructions. CORRECTIVE ACTION 1. 2. 3. 4. Remove any obstructions. Replace any damaged lines, hoses, or fittings, and tighten loose connections (Volume 2, WP 0170). Replace any damaged or leaking steering cylinder (Volume 2, WP 0171). Check for proper operation, Enter into EXTRA FUNCT 2(13)" in the diagnostic menu. Operate the pump cutoff function and observe any change in engine sound. lf no notable change is heard or felt while turning the pumps on and off perform troubleshooting procedure for the 611 valve hydraulic/electrical circuit (Figure 2 & Figure 18 (Volume 2, WP 0272)). 5. Check steering system hydraulic pressures at test points 3, 6, and 7 (Volume 2, WP 0245). a. b. Compare the hydraulic pressures of the test points. All three should be the same 430 to 3,045 psi (2,965 to 20,995 kPa). If pressures are not as specified, replace steering/tophandler pump assembly (Volume 2, WP 0212).

Operators Cab Troubleshooting Procedures (Non-Error Code). SYMPTOM OPERATORS CAB WILL NOT MOVE TO OR FROM TRANSPORT POSITION PROPERLY

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Operators Cab Troubleshooting Procedures (Non-Error Code) - Continued. MALFUNCTION Auxiliary pump improper operation (TM 10-3930-675-10). CORRECTIVE ACTION lf auxiliary pump does not work, use the troubleshooting procedure Auxiliary Pump Not Working" in this work package to correct the problem. MALFUNCTION Cab lift slide rails, rollers, and cab transport lift damaged or obstructed. CORRECTIVE ACTION 1. 2. Repair or replace damaged cab lift slide rails, rollers, or cab transport lift (Volume 2, WP 0179). Remove obstructions and clean as required.

MALFUNCTION Cab lift and sideshift cylinders, hoses, and cab transport control valve damaged or leaking. CORRECTIVE ACTION 1. 2. 3. 4. Replace any damaged or leaking cylinder (Volume 2, WP 0232) and (Volume 2, WP 0233). Replace damaged hoses and tighten loose fittings (Volume 2, WP 0221). Replace damaged or leaking cab transport control valve (Volume 2, WP 0216). Check for proper operation. Use (Volume 2, WP 0245) test point 10 to check auxiliary pump pressure. Ensure the supply valve on the hydraulic tank for the auxiliary pump is open. a. b. Open supply valve (FO-10) (Volume 2, WP 0272). Pump pressure should be around 750 psi (5,171 kPa) no load and 1,595 psi (10,997 kPa) While holding control at full LIFT position. lf pressure is not as specified, replace auxiliary pump (Volume 2, WP 0209).

Auxiliary Pump Troubleshooting Procedures (Non-Error Code). SYMPTOM AUXILIARY PUMP NOT WORKING MALFUNCTION Circuit breaker F17 for Reset circuit breaker as tripped. CORRECTIVE ACTION 1. 2. Reset circuit breaker as required. If breaker does not reset, use the wiring diagram to check circuit for short to ground

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Auxiliary Pump Troubleshooting Procedures (Non-Error Code) - Continued. CORRECTIVE ACTION - Continued (Figure 15 & Figure 16 (Volume 2, WP 0272)). Replace any shorted or grounded harnesses (Volume 2, WP 0267). 3. Replace damaged or faulty circuit breaker (WP 0103).

MALFUNCTION Auxiliary pump damaged. CORRECTIVE ACTION Replace damaged auxiliary pump (Volume 2, WP 0209). MALFUNCTION Auxiliary pump switch inoperative. CORRECTIVE ACTION 1. 2. Replace damaged or inoperable switch (WP 0094). Check for proper operation. Enter EXTRA FUNC 3(13)" in the diagnostic menu. Press the auxiliary pump switch. Should have a 1" for INPUT" then a 1" for OUTPUT". (1) (2) (3) If no 1" for INPUT", continue with No voltage (24V) at X67 pin 1 and 2 while pressing the auxiliary pump switch." If no 1" for OUTPUT", replace ECU 792 (WP 0100). If 1" for OUTPUT", continue with No voltage (24V) at 350-1 solenoid located on top of the auxiliary pump motor."

MALFUNCTION No Voltage (24V) at X67 pin 1 and 2 while pressing the auxiliary pump switch. CORRECTIVE ACTION 1. 2. 3. 4. At X67 pin 1, check circuit breaker FI7 and continuity of wires A678 and A671 (Figure 15 (Volume 2, WP 0272)). At X67 pin 2, remove auxiliary pump switch and check for damage and continuity, and check continuity of wires 671 and 672 (Volume 2, WP 0272). Replace damaged or faulty switch (WP 0094). Repair or replace damaged wires or connectors (Volume 2, WP 0267).

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Auxiliary Pump Troubleshooting Procedures (Non-Error Code) - Continued. MALFUNCTION No voltage at ECU 792 pin 48 while pressing the auxiliary pump switch. CORRECTIVE ACTION 1. 2. At ECU 792 pin 48, check continuity of wires A474, 474, and A1744 (Figure 16 (Volume 2, WP 0272)). Repair or replace damaged wires or connectors (Volume 2, WP 0267).

MALFUNCTION No voltage (24V) at 350-1 solenoid located on top of the auxiliary pump motor. CORRECTIVE ACTION Should have voltage (24V) at the large terminal with the cable (W30) connected to it. a. b. c. Check voltage (24V) at the circuit breakers (F51-1 and FS1-2) mounted under the auxiliary pump (Figure 8 & Figure 16 (Volume 2, WP 0272)). Replace damaged or faulty circuit breakers (WP 0103). Repair or replace damaged wires or connectors (Volume 2, WP 0267).

MALFUNCTION No voltage (24V) between motor +terminal and motor ground terminal with auxiliary pump switch pressed. CORRECTIVE ACTION 1. 2. 3. 4. Test 350-1 solenoid (Volume 2, WP 0267). If 350-1 solenoid damaged or faulty, replace auxiliary pump (Volume 2, WP 0209). Replace auxiliary pump (Volume 2, WP 0209). Repair loose or disconnected ground cables (Figure 16 (Volume 2, WP 0272)).

MALFUNCTION No voltage (24V) at 350-1 solenoid pin 86 (top spade terminal) while pressing the auxiliary pump switch. CORRECTIVE ACTION 1. 2. 3. 4. At 350-1 pin 86, remove relay 350 and test Electrical General Maintenance Instructions (Volume 2, WP 0267) and Figure 16 (Volume 2, WP 0272)). Replace damaged or faulty relay (WP 0103). Check continuity of wires 251, 252, A251, A251A, and A671A (Figure 16 (Volume 2, WP 0272)). Repair or replace damaged wires or connectors (Volume 2, WP 0267).

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Auxiliary Pump Troubleshooting Procedures (Non-Error Code) - Continued. MALFUNCTION No voltage (24V) at XK3 pin 8 While pressing the auxiliary pump switch. CORRECTIVE ACTION 1. 2. 3. At XK3 pin 8, check continuity of wires A469, 469, and A1745 (Figure 16 (Volume 2, WP 0272)). Check Wire connection and voltage (24V With switch pressed) at ECU 792 pin 61 (Figure 16 (Volume 2, WP 0272)). Repair or replace damaged wires or connectors (Volume 2, WP 0267).

Boom System Troubleshooting Procedures (Non-Error Code). SYMPTOM BOOM WILL NOT LIFT OR LOWER PROPERLY MALFUNCTION Active boom system error code(s). CORRECTIVE ACTION Perform troubleshooting procedures to clear error code(s) (WP 0004). MALFUNCTION Boom locked (red) twistlock indicator light is off. CORRECTIVE ACTION 1. 2. Use the override switch to move twistlocks into proper position (TM 10-3930-675-10). If twistlock lights do not operate correctly, perform troubleshooting procedure for Proximity Switches - Tophandler and Cab" in this work package.

MALFUNCTION Lift cylinders are damaged, leak, or have obstructions. CORRECTIVE ACTION 1. 2. Remove any obstructions. Replace damaged or leaking cylinders (Volume 2, WP 0231).

MALFUNCTION Lift cylinder hydraulic lines and hoses damaged and signs of leakage. CORRECTIVE ACTION 1. Tighten loose connections.

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Boom System Troubleshooting Procedures (Non-Error Code) - Continued. CORRECTIVE ACTION - Continued 2. Replace damaged or leaking lines and hoses (Volume 2, WP 0224).

MALFUNCTION Lift cylinder emergency and float valves are not in closed position. CORRECTIVE ACTION Close emergency and float valves as required (TM 10-3930-675-10). MALFUNCTION Boom and tophandler out of calibration (Volume 2, WP 0257). CORRECTIVE ACTION 1. 2. Calibrate boom and tophandler as required (Volume 2, WP 0257). Check test boom control system. Operate the auxiliary pump using the procedure Lower Boom (Extended or Loaded with a Container)" (TM 10-3930-675-10) to test boom control system. (The boom movements will be extremely slow). a. b. 3. If boom system operates normally, the boom control system is not at fault, check boom and brake pump pressure (Volume 2, WP 0245). If boom system does not operate normally, check boom control system.

Test boom system operating pressures at test points 8 and 9 (Volume 2, WP 0245). a. b. c. If test point 9 pressure is not normal, replace servo pressure reducing valve first, then the servo control valve (Volume 2, WP 0207) if needed. lf boom will extend and retract normally, but not lift or lower, replace the main control valve assembly (Volume 2, WP 0214). lf test point 8 pressure is not normal, replace boom and brake system hydraulic pump (Volume 2, WP 0205).

SYMPTOM BOOM WILL NOT EXTEND OR RETRACT PROPERLY MALFUNCTION Active boom system error code(s). CORRECTIVE ACTION Perform troubleshooting procedures to clear error code(s) (WP 0004).

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Boom System Troubleshooting Procedures (Non-Error Code) - Continued. MALFUNCTION Extension cylinder damage or leakage. CORRECTIVE ACTION

NOTE
Extension cylinder leaks appear to be coming from inside boom assembly. Notify SRA to replace damaged or leaking extension cylinder. MALFUNCTION Extension cylinder hydraulic lines and hoses damage or leakage. CORRECTIVE ACTION 1. 2. Tighten loose connections. Replace damaged or leaking lines and hoses (Volume 2, WP 0224).

MALFUNCTION Boom wear plates worn or damaged. CORRECTIVE ACTION Replace worn or damaged boom wear plates (Volume 2, WP 0258). MALFUNCTION Boom and tophandler calibration (Volume 2, WP 0257). CORRECTIVE ACTION 1. 2. Calibrate boom and tophandler as required (Volume 2, WP 0257). Test boom control system. Operate the auxiliary pump using the procedure Lower boom (Extended or Loaded with a Container)" (TM 10-3930-675-10) to test boom control system. (The boom movements will be extremely slow). a. b. 3. lf boom system operates normally, the boom control system is not at fault, check boom and brake pump pressure (Volume 2, WP 0245). lf boom system does not operate normally, check boom control system.

Test boom system operating pressures, test points 8 and 9 (Volume 2, WP 0245). a. b. c. If test point 9 pressure is not normal, replace servo pressure reducing valve first, then the servo control valve (Volume 2, WP 0207) if needed. If boom will extend and retract normally, but not lift or lower, replace the main control valve assembly (Volume 2, WP 0214). lf test point 8 pressure is not normal, replace boom and brake system hydraulic pump (Volume 2, WP 0205).

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Boom System Troubleshooting Procedures (Non-Error Code) - Continued. SYMPTOM BOOM FOLDING CYLINDERS NOT WORKING MALFUNCTION Inoperative tophandler functions. CORRECTIVE ACTION 1. 2. 3. 4. Check operation of all tophandler functions lf no tophandler functions operate, check tophandler pump pressure at test point no. 11 (Volume 2, WP 0245). Troubleshooting pump control circuit (611 solenoid) (Figure 18 & Figure 2 (Volume 2, WP 0272)). Replace steering and tophandler pump assembly (Volume 2, WP 0212).

MALFUNCTION Incorrect clearance of cab proximity switch (7210) between cab and frame. CORRECTIVE ACTION Move cab closer to the frame. MALFUNCTION Cab position incorrect. CORRECTIVE ACTION Adjust cab or proximity switch (7210) to correct clearance. MALFUNCTION Boom folding control valve damaged or leakage. CORRECTIVE ACTION

NOTE
DO NOT adjust proximity switch (7210) beyond end of enclosure. Replace damaged or leaking boom folding control valve(s) (Volume 2, WP 0215). MALFUNCTION Damaged boom folding cylinders. CORRECTIVE ACTION Replace damaged or leaking boom folding (Volume 2, WP 0218).

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Boom System Troubleshooting Procedures (Non-Error Code) - Continued. MALFUNCTION Hydraulic lines and hoses and boom folding control valve for damage and signs of leakage. CORRECTIVE ACTION 1. 2. 3. 4. SYMPTOM BOOM LOCKING PIN CYLINDER NOT WORKING MALFUNCTION Incorrect operation of all tophandler functions. CORRECTIVE ACTION 1. 2. 3. If no tophandler functions operate, check tophandler pump pressure at test point no. 11 (Volume 2, WP 0245). Troubleshoot pump control circuit (611 solenoid) (Figure 2 & Figure 18 (Volume 2, WP 0272)). Replace steering and tophandler pump assembly (Volume 2, WP 0212). Replace damaged or leaking lines and hoses (Volume 2, WP 0223). Replace damaged or leaking boom folding control valve (Volume 2, WP 0215). Tighten loose connections. Replace the over-center valve (Volume 2, WP 0224).

MALFUNCTION Incorrect clearance of cab proximity switch (7210) between cab and frame. CORRECTIVE ACTION

NOTE
Move the cab to the transport position (TM 10-3930-675-10). Raise boom folding cylinders to release pressure on locking pins before operating locking pin cylinders. 1. 2. Move cab closer to the frame. Adjust cab or proximity switch (7210) to correct clearance.

MALFUNCTION Boom folding control valve damaged and signs of leakage. CORRECTIVE ACTION Replace damaged or leaking boom folding control valve(s) (WP 0118).

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Boom System Troubleshooting Procedures (Non-Error Code) - Continued. MALFUNCTION Damaged cab proximity switch (7210). CORRECTIVE ACTION

NOTE
DO NOT adjust proximity switch (7210) beyond end of enclosure. Replace damaged or inoperative proximity switch (WP 0105). MALFUNCTION Solenoid valve (6043) operation and wiring (Figure 7 (Volume 2, WP 0272)). CORRECTIVE ACTION Replace damaged or faulty solenoid valve (Volume 2, WP 0217). MALFUNCTION Damaged locking pin cylinders CORRECTIVE ACTION Replace damaged or leaking locking pin cylinder(s) (Volume 2, WP 0235). MALFUNCTION Hydraulic line and hoses damaged or signs of leakage. CORRECTIVE ACTION 1. 2. Tighten loose connections. Replace damaged or leaking lines and hoses (Volume 2, WP 0220).

MALFUNCTION Locking pins damaged. CORRECTIVE ACTION Check for frame or boom support damage. MALFUNCTION Damaged double pilot operated check valve mounted on the locking pin cylinder. CORRECTIVE ACTION Replace double pilot operated check valve (Volume 2, WP 0224).

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Tophandler System Troubleshooting Procedures (Non-Error Code). SYMPTOM TOPHANDLER WILL NOT TILT FORWARD OR REARWARD PROPERLY MALFUNCTION Active tophandler ERROR CODE(s). CORRECTIVE ACTION 1. 2. Perform troubleshooting for active code(s) (WP 0004). Check operation of all tophandler functions. a. b. c. If no tophandler functions operate, check tophandler pump pressure at test point 11 (Volume 2, WP 0245). Troubleshoot pump control circuit (611 solenoid) (Figure 2 & Figure 18 (Volume 2, WP 0272)). Replace steering and tophandler pump assembly (Volume 2, WP 0212).

MALFUNCTION Damaged tophandler control valves, lines, hoses. CORRECTIVE ACTION Replace any damaged line, hoses, or fittings, and tighten loose connections (Volume 2, WP 0225). MALFUNCTION Tilt cylinders damaged, leaking or obstructed. CORRECTIVE ACTION 1. 2. 3. Remove any obstructions. Connect any disconnected quick-disconnect fittings (Volume 2, WP 0245). Replace damaged or leaking tilt cylinder (Volume 2, WP 0237).

MALFUNCTION Tophandler control valve solenoids 6010 and 6011 damaged or leaking. CORRECTIVE ACTION 1. Replace damaged or leaking solenoid (Volume 2, WP 0217).

WARNING
Injury or death can occur during manual operation of the hydraulic function.

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Tophandler System Troubleshooting Procedures (Non-Error Code) - Continued. CORRECTIVE ACTION - Continued

CAUTION
Be careful not to lose the small orifice plug inside the solenoid valve body when removing the solenoid. 2. Check for proper operation. Start engine (TM 10-3930-675-10). Disconnect the connector from the 6010 and 6011 solenoids. Locate the small brass button between the two connector pins on the solenoid. Use jewelers screwdriver to press the button momentarily to manually activate the tilt function. Check both solenoids the same way. a. b. SYMPTOM TOPHANDLER WILL NOT OSCILLATE (LEVEL) PROPERLY MALFUNCTION Active tophandler ERROR CODE(s). CORRECTIVE ACTION 1. 2. Perform troubleshooting for active error code(s) (WP 0004). Check operation of all tophandler functions. a. b. c. If no tophandler functions operate, check tophandler pump pressure at test point 11 (Volume 2, WP 0245). Troubleshoot pump control circuit (611 solenoid) (Figure 2 & Figure 18 (Volume 2, WP 0272)). Replace steering and tophandler pump assembly (Volume 2, WP 0212). Replace damaged or faulty solenoid (Volume 2, WP 0217). Replace the tilt-over cylinder valve.

MALFUNCTION Damaged tophandler control valve. CORRECTIVE ACTION Replace any damaged line, hoses, or fittings, and tighten loose connections (Volume 2, WP 0225). MALFUNCTION Lines hoses, and oscillation cylinders damaged, leaking, or obstructed. CORRECTIVE ACTION 1. 2. 3. Remove any obstructions. Connect any disconnected quick-disconnect fittings (Volume 2, WP 0225). Replace damaged or leaking oscillation or tophandler.

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Tophandler System Troubleshooting Procedures (Non-Error Code) - Continued. MALFUNCTION Oscillation wear plates damaged and worn. CORRECTIVE ACTION Replace any worn or damaged wear plates. MALFUNCTION Tophandler control valve solenoids 6035 and 6036 damaged or leaking. CORRECTIVE ACTION 1. Replace damaged or leaking solenoid (Volume 2, WP 0217).

WARNING
Injury or death can occur during manual operation of the hydraulic function. 2. Check for proper operation. Start the engine (TM 10-3930-675-10). Disconnect the connector from the 6035 and 6036 solenoids. Locate the small brass button between the two connector pins on the solenoid. Use a jewelers screwdriver to press the button momentarily to manually activate the oscillate function. Check both solenoids the same way. a. b. c. If the function does not activate, remove the solenoid and inspect (Volume 2, WP 0217). Replace damaged or faulty solenoid (Volume 2, WP 0217). Replace the oscillate over-center valve.

MALFUNCTION Active tophandler ERROR CODE(s). CORRECTIVE ACTION 1. 2. Perform troubleshooting for active ERROR CODE(s). Check operation of all tophandler functions. a. b. c. If no tophandler functions operate, check tophandler pump pressure at test point 11 (Volume 2, WP 0245). Troubleshoot pump control circuit (611 solenoid) (Figure 18 (Volume 2, WP 0272)). Replace steering and tophandler pump assembly (Volume 2, WP 0212).

MALFUNCTION Damaged tophandler control valve. CORRECTIVE ACTION Replace any damaged line, hoses, or fittings, and tighten loose connections (Volume 2, WP 0225).

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Tophandler System Troubleshooting Procedures (Non-Error Code) - Continued. MALFUNCTION Lines, hoses, and sideshift cylinders damaged, leaking, or obstructed. CORRECTIVE ACTION 1. 2. 3. Remove any obstructions. Connect any disconnected quick-disconnect fittings (Volume 2, WP 0225). Replace damaged or leaking oscillation or tophandler control valve (Volume 2, WP 0230).

MALFUNCTION Sideshift wear plates damaged or worn. CORRECTIVE ACTION Replace any worn or damaged wear plates (Volume 2, WP 0263). MALFUNCTION Tophandler control valve solenoids 6020 and 6021 damaged or leaking. CORRECTIVE ACTION 1. Replace damaged or leaking solenoid (Volume 2, WP 0217).

WARNING
Injury or death can occur during manual operation of the hydraulic function.

CAUTION
Be careful not to lose the small orifice plug inside the solenoid valve body when removing the solenoid. 2. Check for proper operation. Start engine (TM 10-3930-675-10). Disconnect the connector from the 6020 and 6021 solenoids. Locate the small brass button between the two connector pins on the solenoid. Use a jewelers screwdriver to press the button momentarily to manually activate the sideshift function. Check both solenoids the same way. Replace damaged or faulty solenoid (Volume 2, WP 0217). SYMPTOM TOPHANDLER SPREADER WILL NOT OPEN OR CLOSE PROPERLY MALFUNCTION Active tophandler ERROR CODE(s). CORRECTIVE ACTION 1. Perform troubleshooting for active error code(s) (WP 0004).

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Tophandler System Troubleshooting Procedures (Non-Error Code) - Continued. CORRECTIVE ACTION - Continued 2. Check operation of all tophandler functions. a. b. c. If no tophandler functions operate, check tophandler pump pressure at test point 11 (Volume 2, WP 0245). Troubleshoot pump control circuit (611 solenoid) (Figure 2 & Figure 18 (Volume 2, WP 0272)). Replace steering and tophandler pump assembly (Volume 2, WP 0212).

MALFUNCTION Incorrect position of twistlocks. CORRECTIVE ACTION Place twistlocks in the UNLOCKED position. If twistlocks do not operate, ensure cab is in operational position. MALFUNCTION Incorrect operation of the forklift kit proximity switches and cam mechanism. CORRECTIVE ACTION Ensure both proximity switches are activated and cam mechanism operates properly. MALFUNCTION Damaged lines, hoses. CORRECTIVE ACTION Replaced damaged line, hoses, or fittings, and tighten loose connections (Volume 2, WP 0225). MALFUNCTION Spreader motor damaged, leaking, or obstructed. CORRECTIVE ACTION 1. 2. 3. Remove any obstructions. Connect any disconnected quick-disconnect fittings (Volume 2, WP 0225). Replace damaged or leaking, spreader motor (WP 0126).

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Tophandler System Troubleshooting Procedures (Non-Error Code) - Continued. MALFUNCTION Spreader chains and sprockets damaged, wear, tightness, or obstructions. CORRECTIVE ACTION Replace or adjust damaged, worn, or loose spreader chains (Volume 2, WP 0260). MALFUNCTION Spreader wear plates damaged or wear. CORRECTIVE ACTION Replace any worn or damaged wear plates (Volume 2, WP 0263). MALFUNCTION Tophandler control valve solenoids 6018 and 6019 damaged or leaking. CORRECTIVE ACTION 1. Replace damaged or leaking solenoid (Volume 2, WP 0217).

WARNING
Injury or death can occur during manual operation of the hydraulic function.

CAUTION
Be careful not to lose the small orifice plug inside the solenoid valve body when removing the solenoid. 2. Check for proper operation. Start engine (TM 10-3930-675-10). Disconnect the connector from the 6018 and 6019 solenoids. Locate the small brass button between the two connector pins on the solenoid. Use a jewelers screwdriver to press the button momentarily to manually activate the sideshift function. Check both solenoids the same way. a. b. c. SYMPTOM TOPHANDLER WILL NOT ROTATE LEFT OR RIGHT PROPERLY MALFUNCTION Active tophandler ERROR CODE(s). CORRECTIVE ACTION 1. Perform a troubleshooting for active error code(s) (WP 0004). Replace damaged or faulty solenoid (Volume 2, WP 0217). Replace the spreader motor over-center valve (WP 0126). Replace spreader motor assembly (WP 0126).

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Tophandler System Troubleshooting Procedures (Non-Error Code) - Continued. CORRECTIVE ACTION - Continued 2. Check operation of all tophandler functions. a. b. c. If not tophandler functions operate, check tophandler pump pressure at test point 11 (Volume 2, WP 0245). Troubleshoot pump control circuit (611 solenoid) (Figure 2 & Figure 18 (Volume 2, WP 0272)). Replace steering and tophandler pump assembly (Volume 2, WP 0212).

MALFUNCTION Damaged tophandler control valve. CORRECTIVE ACTION Replace any damaged line, hoses, or fittings, and tighten loose connections (Volume 2, WP 0225). MALFUNCTION Lines, hoses, and slewing motors damaged, leaking, or obstructed. CORRECTIVE ACTION 1. 2. 3. Remove any obstructions. Connect any disconnected quick-disconnect fittings (Volume 2, WP 0225). Replace damaged or leaking slewing motor (Volume 2, WP 0210).

MALFUNCTION Slewing gear and pinions damaged, worn, or obstructed. CORRECTIVE ACTION 1. 2. Replace any worn or damaged slewing motor and pinion (Volume 2, WP 0210). Replace damaged or worn slewing gear (Volume 2, WP 0210).

MALFUNCTION Tophandler control valve solenoids 6008 and 6009 damaged or leaking. CORRECTIVE ACTION 1. Replace damaged or leaking solenoid (Volume 2, WP 0217).

WARNING
Injury or death can occur during manual operation of the hydraulic function.

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Tophandler System Troubleshooting Procedures (Non-Error Code) - Continued. CORRECTIVE ACTION - Continued

CAUTION
Be careful not to lose the small orifice plug inside the solenoid valve body when removing the solenoid. 2. Check for proper operation. Start engine (TM 10-3930-675-10). Disconnect the connector from the 6008 and 6009 solenoids. Locate the small brass button between the two connector pins on the solenoid. Use a jewelers screwdriver to press the button momentarily to manually activate the sideshift function. Check both solenoids the same way. a. b. c. d. SYMPTOM TOPHANDLER TWISTLOCKS WILL NOT ROTATE PROPERLY MALFUNCTION Active tophandler ERROR CODE(s). CORRECTIVE ACTION 1. 2. Perform troubleshooting for active error code(s) (WP 0004). Check operation of all tophandler functions. a. b. c. If no tophandler functions operate, check tophandler pump pressure at test point 11 (Volume 2, WP 0245). Troubleshoot pump control circuit (611 solenoid) (Figure 2 & Figure 18 (Volume 2, WP 0272)). Replace steering and tophandler pump assembly (Volume 2, WP 0212). If the function does not activate, remove the solenoid and inspect (Volume 2, WP 0217). Replace damaged or faulty solenoid (Volume 2, WP 0217). Replace the slewing motor over center valve (Volume 2, WP 0210). Replace slewing motor assembly (Volume 2, WP 0210).

MALFUNCTION Incorrect position of the cab. CORRECTIVE ACTION Place cab operational position (TM 10-3930-675-10). MALFUNCTION Incorrect position of twistlocks cylinder bypass valves. CORRECTIVE ACTION Place both valves in proper position.

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Tophandler System Troubleshooting Procedures (Non-Error Code) - Continued. MALFUNCTION Damaged bypass valves, lines, hoses. CORRECTIVE ACTION Replace any damaged bypass valve lines, hoses, or fittings, and tighten loose connections (Volume 2, WP 0225). MALFUNCTION Twistlock cylinders damaged, leaking, or obstructed. CORRECTIVE ACTION 1. 2. Remove any obstructions. Replace damaged or leaking twistlock cylinder (Volume 2, WP 0240).

MALFUNCTION Twistlocks and linkage arms damaged or obstructions. CORRECTIVE ACTION 1. 2. Remove obstructions. Replace damaged twistlocks or linkage (Volume 2, WP 0203).

MALFUNCTION Tophandler control valve solenoids 6039 and 6040 damaged or leaking. CORRECTIVE ACTION 1. Replace damaged or leaking solenoid (Volume 2, WP 0217).

WARNING
Injury or death can occur during manual operation of the hydraulic function.

CAUTION
Be careful not to lose the small orifice plug inside the solenoid valve body when removing the solenoid. 2. Check for proper operation. Start engine (TM 10-3930-675-10). Disconnect the connector from the 6039 and 6040 solenoids. Locate the small brass button between the two connector pins on the solenoid. Use a jewelers screwdriver to press the button momentarily to manually activate the sideshift function. Check both solenoids the same way. a. b. c. If the function does not activate, remove the solenoid and inspect (Volume 2, WP 0217). Replace damaged or faulty solenoid (Volume 2, WP 0217). Replace twistlock double pilot operated check valve (Volume 2, WP 0240).

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Bogie Wheel System Troubleshooting Procedures (Non-Error Code). SYMPTOM BOGIE WHEELS WILL NOT LIFT OR LOWER MALFUNCTION Tophandler functions inoperative. CORRECTIVE ACTION Check operation of all tophandler functions. a. b. c. If no tophandler functions operate, check tophandler pump pressure at test. Troubleshoot pump control circuit (611 solenoid) (Figure 2 & Figure 18 (Volume 2, WP 0272)). Replace steering ad tophandler pump assembly (Volume 2, WP 0212).

MALFUNCTION Incorrect clearance of cab proximity switch (7210) between cab and frame. CORRECTIVE ACTION

NOTE
Move the cab to the transport position (TM 10-3930-675-10). DO NOT adjust proximity switch (7210) beyond end of enclosure. 1. 2. Move cab closer to the frame. Adjust cab or proximity switch (7210) to correct clearance.

MALFUNCTION Bogie wheel slide rails and locking collar/bogie screw obstructions. CORRECTIVE ACTION Remove obstructions and clean as required. MALFUNCTION Incorrect position of bogie pressure valve. CORRECTIVE ACTION Place bogie pressure valve in the CLOSED position (TM 10-3930-675-10).

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Bogie Wheel System Troubleshooting Procedures (Non-Error Code) - Continued. MALFUNCTION Boom folding control valve damaged or leakage. CORRECTIVE ACTION Replace damaged or leaking boom folding control valve (Volume 2, WP 0215). MALFUNCTION Inoperative cab proximity switch (7210). CORRECTIVE ACTION Replace damaged or inoperative proximity switch (WP 0105). MALFUNCTION Solenoid valve (6043) operation or wiring damaged (Figure 7 (Volume 2, WP 0272)). CORRECTIVE ACTION Replace damaged or faulty solenoid valve (Volume 2, WP 0217). MALFUNCTION Damaged bogie wheel cylinders. CORRECTIVE ACTION Replace damaged or leaking lines and hoses (Volume 2, WP 0224). MALFUNCTION Hydraulic lines and hoses and boom folding control valve damaged or signs of leakage. CORRECTIVE ACTION 1. 2. 3. 4. Tighten loose connections. Replace damaged or leaking boom folding control valve (Volume 2, WP 0215). Replace damaged or leaking bogie wheel cylinder(s) (Volume 2, WP 0234). Replace the over-canter valve (Volume 2, WP 0224).

Forklift Kit Troubleshooting Procedures (Non-Error Code). SYMPTOM FORK FUNCTIONS NOT WORKING PROPERLY

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Forklift Kit Troubleshooting Procedures (Non-Error Code) - Continued. MALFUNCTION Active tophandler error code(s). CORRECTIVE ACTION 1. 2. Perform troubleshooting for active error code(s) (WP 0004). Check operation of all tophandler functions. a. b. c. 3. If no tophandler functions operate, check tophandler pump pressure at test point 11 (Volume 2, WP 0245). Troubleshoot pump control circuit (611 solenoid) (Figure 2 & Figure 18 (Volume 2, WP 0272)). Replace steering and tophandler pump assembly (Volume 2, WP 0212).

Check operation of forklift kit proximity switches ad cam mechanism. Ensure both proximity switches are active and cam mechanism operates properly.

MALFUNCTION Damaged lines, hoses. CORRECTIVE ACTION Replace any damaged line, hoses, or fittings, and tighten loose connections (Volume 2, WP 0225). MALFUNCTION Cylinders damaged or leaking. CORRECTIVE ACTION 1. 2. Connect any disconnected quick-disconnect fittings (Volume 2, WP 0225). Replace any damaged or leaking cylinders (Volume 2, WP 0246).

MALFUNCTION Fork wear plates and shaft sliding surfaces damaged, worn, or obstructed. CORRECTIVE ACTION 1. 2. Remove any obstructions. Replace any worn or damaged wear plates.

MALFUNCTION Forklift hydraulic valves damaged or leaking. CORRECTIVE ACTION Replace any damaged or leaking hydraulic valves (Volume 2, WP 0226).

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Autolube System (RT 240V2 and RT 240V3) Troubleshooting Procedures (Non-Error Code). SYMPTOM AUTOLUBE SYSTEM NOT LUBRICATING PROPER MALFUNCTION Autolube pump inoperative. CORRECTIVE ACTION 1. 2. Initiate a manual pump cycle (WP 0047). Perform troubleshooting procedure for Autolube Pump Not Working (RT 240V2 and RT 240V3)" in this is not work package.

MALFUNCTION Main distribution valve damaged. CORRECTIVE ACTION 1. 2. Observe if the pin is moving in and out during a manual cycle. Replace damaged main distribution valve.

MALFUNCTION Lubricant leaking from pressure limiting valve. CORRECTIVE ACTION 1. 2. 3. Disconnect each outlet tube one at a time at the distribution valve. Identify the tube that had pressure on it when disconnected. Reconnect the tubes and run a manual lube cycle.

MALFUNCTION Use the Autolube tubing layout diagram (Figure 23 (Volume 2, WP 0272)) to trace the identified tube to the secondary distribution valve. CORRECTIVE ACTION 1. 2. 3. 4. Disconnect each outlet tube at the secondary distribution valve one at a time until you identify the one with pressure on it. Use the tubing layout diagram to trace identified tube to the plugged" lube point. If no plugged" lube points are found, run a manual lube cycle and disconnect the inlet tube at each secondary distribution valve to identify the tube with pressure in it. Replace non-functioning or plugged" secondary distribution valve.

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Autolube System (RT 240V2 and RT 240V3) Troubleshooting Procedures (Non-Error Code) - Continued. MALFUNCTION Autolube system tubing and fittings damaged or worn. CORRECTIVE ACTION Replace any damaged or worn tubing or fittings. SYMPTOM AUTOLUBE PUMP NOT WORKING MALFUNCTION Circuit breaker F43 tripped. CORRECTIVE ACTION 1. 2. Reset circuit breaker as required. Replace damaged or faulty circuit breaker (WP 0103).

MALFUNCTION Autolube pump damaged. CORRECTIVE ACTION 1. 2. 3. Replace damaged Autolube pump. Enter EXTRA FUNC 10(13)" in the diagnostic menu. Use the +/- keys to activate pump control circuit. SET OUTPUT SIG" should be 1" when activated. Remove the plastic plug from the front of the Autolube pump. Check the left LED light on the pump printed circuit board is on. Push the button on the PC board for two seconds to activate a manual cycle.

MALFUNCTION No voltage (24V) at X174B pin 2. CORRECTIVE ACTION 1. 2. 3. 4. At X174B pin 2, check connection of wire A174B2 at ECU (792) pin 60. Check continuity of wire A174B2. Repair or replace damaged wires or connectors (Volume 2, WP 0267). Replace ECU (729) (WP 0100).

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0006

Autolube System (RT 240V2 and RT 240V3) Troubleshooting Procedures (Non-Error Code) - Continued. MALFUNCTION Access the relay boards inside the cab distribution box. Activate the pump control. No voltage (24V) at XK1 pin 8 when pump control activated. CORRECTIVE ACTION 1. 2. If no voltage (24V) is found at XK1 pin 8, check continuity of wires 476 and A476. Repair or replace damaged wires or connectors (Volume 2, WP 0267).

MALFUNCTION Relay 3018 damaged. CORRECTIVE ACTION Replace damaged or faulty relay (WP 0103). MALFUNCTION No voltage (24V) at XK1 pin 9 and pin 3 while activating the pump control. CORRECTIVE ACTION 1. 2. 3. At XK1 pin 9, check circuit breaker F34 and continuity of wire A341. If no voltage (24V) is found at XK1 pin 3, replace relay 3018. Repair or replace damaged wires or connectors (Volume 2, WP 0267).

MALFUNCTION No voltage (24V) at X31 pin 8 with pump activated. CORRECTIVE ACTION 1. 2. 3. At X31 pin 8, check continuity of wire A318. Repair or replace damaged wires or connectors (Volume 2, WP 0267). Unplug connector at pump and check for 24V between the two pins. a. b. c. If voltage (24V) is present, replace the Autolube pump. If voltage (24V) is not present, check the continuity of wires GY and BK in the pump harness and the ground connections of wire A319 and 371 in the cab distribution box in the cab. Replace damaged or open Autolube harness.

MALFUNCTION Solar panel damaged. CORRECTIVE ACTION Replace damaged solar panel (WP 0106).

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0006

Autolube System (RT 240V2 and RT 240V3) Troubleshooting Procedures (Non-Error Code) - Continued. MALFUNCTION Wiring connections damaged. CORRECTIVE ACTION Replace/repair damaged wires (Volume 2, WP 0267). MALFUNCTION Blown 2 amp fuse located in the fuse holder on the RED wire connected to the master battery switch battery side terminal (Figure 2 (Volume 2, WP 0272)). CORRECTIVE ACTION Replace blown 2 amp fuse (WP 0106). MALFUNCTION 24V Pulse module or connection damaged (Figure 8 (Volume 2, WP 0272)). CORRECTIVE ACTION 1. 2. Blinking red LED on 24V Pulse module indicates voltage is connected and unit is operating. Replace damaged non-functioning 24V Pulse module (WP 0106).

END OF WORK PACKAGE

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0007

FIELD MAINTENANCE ENGINE FUEL INJECTOR CIRCUITS TROUBLESHOOTING

INITIAL SETUP: Tools and Special Tools Lead, Test (Volume 2, WP 0277, Table 1, Item 47) Lead, Test (Volume 2, WP 0277, Table 1, Item 49) Multimeter (Volume 2, WP 0277, Table 1, Item 52) References WP 0005 References (cont.) WP 0057 WP 0067 WP 0099 WP 0100 Volume 2, WP 0267

NOTE
Refer to Troubleshooting Symptom Index (WP 0005) for additional troubleshooting guidance, information, and illustrations that locate critical components.

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0007

TROUBLESHOOTING PROCEDURE ENGINE FUEL INJECTOR CIRCUITS TROUBLESHOOTING

WARNING

Injector solenoids receive high voltage when engine is operating. To avoid personal injury or death from electrical shock, do not wear jewelry or damp clothing, and do not touch injector solenoids or solenoid wires when engine is operating. SYMPTOM

ERROR CODE 1311 MALFUNCTION Injector Circuit Failure. CORRECTIVE ACTION 1. Place ignition switch in OFF position and disconnect actuator harness from engine Electronic Control Unit (ECU) and from 15-pin connector at front of engine below rocker arm cover. a. Inspect actuator harness, actuator harness connector, and 15-pin connector for dirty, corroded, bent, broken, pushed back, and extended pins. Clean and repair connector(s) as required (Volume 2, WP 0267). Check actuator harness, actuator harness connector, and 15-pin connector for dirt or moisture in or on connector and for missing or damaged connector seals. Remove dirt and moisture from connector. Replace missing or damaged connector seals (Volume 2, WP 0267).

b.

2.

Place ignition switch in OFF position and disconnect actuator harness and sensor harness from engine ECU and actuator harness from 15-pin connector at front of engine below rocker arm cover. Perform the following resistance checks: a. Measure resistance from actuator harness connector pin 9 to all other pins in actuator harness connector. Resistance should be greater than 100k Ohms. (1) (2) b. If resistance is not as specified, repair or replace connectors (Volume 2, WP 0267). If internal actuator harness requires replacement, notify SRA.

Measure resistance from actuator harness connector pin 9 to all other pins in sensor harness connector. Resistance should be greater than 100k Ohms. (1) (2) If resistance is not as specified, repair or replace connectors (Volume 2, WP 0267). If internal actuator harness requires replacement, notify SRA.

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0007

ENGINE FUEL INJECTOR CIRCUITS TROUBLESHOOTING - Continued CORRECTIVE ACTION - Continued

>100K OHMS

>100K OHMS
T0041JCH

Figure 1. Actuator Harness Test. c. Measure resistance from actuator harness connector pin 10 to all other pins in actuator harness connector. Resistance should be greater than 100k Ohms. (1) (2) d. If resistance is not as specified, repair or replace connectors (Volume 2, WP 0267). If internal actuator harness requires replacement, notify SRA.

Measure resistance from actuator harness connector pin 10 to all other pins in sensor harness connector. Resistance should be greater than 100k Ohms. (1) (2) If resistance is not as specified, repair or replace connectors (Volume 2, WP 0267). If internal actuator harness requires replacement, notify SRA.

3.

Place ignition switch in OFF position and disconnect actuator harness from engine ECU. Remove rocker arm cover (WP 0057). Disconnect internal actuator harness from 15-pin connector. a. Inspect actuator harness connector, engine ECU connector, and 15-pin connector for dirty, corroded, bent, broken, pushed back, and extended pins. Clean and repair connector(s) as required (Volume 2, WP 0267). b. Check actuator harness connector, engine ECU connector, and 15-pin connector for dirt or moisture in or on connector and for missing or damaged connector seals. Remove dirt and moisture from connector. Replace missing or damaged connector seals (Volume 2, WP 0267).

4.

Place ignition switch in OFF position and disconnect internal actuator harness from 15-pin connector and from no. 1 injector solenoid. a. Measure resistance from 15-pin connector pin 1 to all other pins in connector. Resistance should be greater than 100k Ohms. (1) (2) b. If resistance is not as specified, repair or replace connectors (Volume 2, WP 0267). If internal actuator harness requires replacement, notify SRA.

Measure resistance from 15-pin connector pin 2 to all other pins in connector. Resistance should be greater than 100k Ohms.

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0007

ENGINE FUEL INJECTOR CIRCUITS TROUBLESHOOTING - Continued CORRECTIVE ACTION - Continued (1) (2) 5. 6. If resistance is not as specified, repair or replace connectors (Volume 2, WP 0267). If internal actuator harness requires replacement, notify SRA.

Place ignition switch in OFF position and, with rocker arm cover removed, disconnect internal actuator harness from injector solenoid. Measure resistance from injector solenoid pin A to pin B. Resistance should be 0.5 to 1.5 Ohms. a. b. If resistance is as specified, replace engine ECU (WP 0100). If resistance is not as specified, replace injector (WP 0067).

7. 8.

Place ignition switch in OFF position and, with rocker arm cover removed, disconnect internal actuator harness from injector solenoid and remove injector solenoid wires from solenoid. Measure resistance from post to post on solenoid. Resistance should be 0.5 to 1.5 Ohms. If resistance is not as specified, replace injector (WP 0067).

SYMPTOM

ERROR CODE 1312 MALFUNCTION Injector Circuit Failure. CORRECTIVE ACTION

WARNING

Injector solenoids receive high voltage when engine is operating. To avoid personal injury or death from electrical shock, do not wear jewelry or damp clothing, and do not touch injector solenoids or solenoid wires when engine is operating. 1. Place ignition switch in OFF position and disconnect actuator harness from engine ECU and from 15-pin connector at front of engine below rocker arm cover. a. Inspect actuator harness, actuator harness connector, and 15-pin connector for dirty, corroded, bent, broken, pushed back, and extended pins. Clean and repair connector(s) as required (Volume 2, WP 0267). b. Check actuator harness, actuator harness connector, and 15-pin connector for dirt or moisture in or on connector and for missing or damaged connector seals. Remove dirt and moisture from connector. Replace missing or damaged connector seals (Volume 2, WP 0267).

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0007

ENGINE FUEL INJECTOR CIRCUITS TROUBLESHOOTING - Continued CORRECTIVE ACTION - Continued 2. Place ignition switch in OFF position and disconnect actuator harness and sensor harness from engine ECU and actuator harness from 15-pin connector at front of engine below rocker arm cover. Perform the following resistance checks. a. Measure resistance from actuator harness connector pin 3 to all other pins in actuator harness connector. Resistance should be greater than 100k Ohms. (1) (2) b. If resistance is not as specified, repair or replace connectors (Volume 2, WP 0267). If internal actuator harness requires replacement, notify SRA.

Measure resistance from actuator harness connector pin 3 to all other pins in sensor harness connector. Resistance should be greater than 100k Ohms. (1) (2) If resistance is not as specified, repair or replace connectors (Volume 2, WP 0267). If internal actuator harness requires replacement, notify SRA.

c.

Measure resistance from actuator harness connector pin 4 to all other pins in actuator harness connector. Resistance should be greater than 100k Ohms. (1) (2) If resistance is not as specified, repair or replace connectors (Volume 2, WP 0267). If internal actuator harness requires replacement, notify SRA.

d.

Measure resistance from actuator harness connector pin 4 to all other pins in sensor harness connector. Resistance should be greater than 100k Ohms. (1) (2) If resistance is not as specified, repair or replace connectors (Volume 2, WP 0267). If internal actuator harness requires replacement, notify SRA.

>100K OHMS
T0042JCH

Figure 2. Actuator Harness Test.

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0007

ENGINE FUEL INJECTOR CIRCUITS TROUBLESHOOTING - Continued CORRECTIVE ACTION - Continued 3. Place ignition switch in OFF position and disconnect actuator harness from engine ECU. Remove rocker arm cover (WP 0057). Disconnect internal actuator harness from 15-pin connector. a. Inspect actuator harness connector, engine ECU connector, and 15-pin connector for dirty, corroded, bent, broken, pushed back, and extended pins. Clean and repair connector(s) as required (Volume 2, WP 0267). b. Check actuator harness connector, engine ECU connector, and 15-pin connector for dirt or moisture in or on connector and for missing or damaged connector seals. Remove dirt and moisture from connector. Replace missing or damaged connector seals (Volume 2, WP 0267). 4. Place ignition switch in OFF position and disconnect internal actuator harness from 15-pin connector and from no. 5 injector solenoid. a. Measure resistance from 15-pin connector pin 9 to all other pins in connector. Resistance should be greater than 100k Ohms. (1) (2) b. If resistance is not as specified, repair or replace connectors (Volume 2, WP 0267). If internal actuator harness requires replacement, notify SRA.

Measure resistance from 15-pin connector pin 10 to all other pins in connector. Resistance should be greater than 100k Ohms. (1) (2) If resistance is not as specified, repair or replace connectors (Volume 2, WP 0267). If internal actuator harness requires replacement, notify SRA.

5. 6.

Place ignition switch in OFF position and, with rocker arm cover removed, disconnect internal actuator harness from injector solenoid. Measure resistance from injector solenoid pin A to pin B. Resistance should be 0.5 to 1.5 Ohms. a. b. If resistance is as specified, replace engine ECU (WP 0100). If resistance is not as specified, replace injector (WP 0067).

7. 8.

Place ignition switch in OFF position and, with rocker arm cover removed, disconnect internal actuator harness from injector solenoid and remove injector solenoid wires from solenoid. Measure resistance from post to post on solenoid. Resistance should be 0.5 to 1.5 Ohms. If resistance is not as specified, replace injector (WP 0067).

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0007

ENGINE FUEL INJECTOR CIRCUITS TROUBLESHOOTING - Continued

SYMPTOM

ERROR CODE 1313 MALFUNCTION Injector Circuit Failure. CORRECTIVE ACTION

WARNING

Injector solenoids receive high voltage when engine is operating. To avoid personal injury or death from electrical shock, do not wear jewelry or damp clothing, and do not touch injector solenoids or solenoid wires when engine is operating. 1. Place ignition switch in OFF position and disconnect actuator harness from engine ECU and from 15-pin connector at front of engine below rocker arm cover. a. Inspect actuator harness, actuator harness connector, and 15-pin connector for dirty, corroded, bent, broken, pushed back, and extended pins. Clean and repair connector(s) as required (Volume 2, WP 0267). b. Check actuator harness, actuator harness connector, and 15-pin connector for dirt or moisture in or on connector and for missing or damaged connector seals. Remove dirt and moisture from connector. Replace missing or damaged connector seals (Volume 2, WP 0267).

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0007

ENGINE FUEL INJECTOR CIRCUITS TROUBLESHOOTING - Continued CORRECTIVE ACTION - Continued 2. Place ignition switch in OFF position and disconnect actuator harness and sensor harness from engine ECU and actuator harness from 15-pin connector at front of engine below rocker arm cover. Perform the following resistance checks: a. Measure resistance from actuator harness connector pin 6 to all other pins in actuator harness connector. Resistance should be greater than 100k Ohms. (1) (2) If resistance is not as specified, repair or replace connectors (Volume 2, WP 0267). If internal actuator harness requires replacement, notify SRA.

>100K OHMS

T0043JCH

Figure 3. Actuator Harness Test. b. Measure resistance from actuator harness connector pin 6 to all other pins in sensor harness connector. Resistance should be greater than 100k Ohms. (1) (2) c. If resistance is not as specified, repair or replace connectors (Volume 2, WP 0267). If internal actuator harness requires replacement, notify SRA.

Measure resistance from actuator harness connector pin 16 to all other pins in actuator harness connector. Resistance should be greater than 100k Ohms. (1) (2) If resistance is not as specified, repair or replace connectors (Volume 2, WP 0267). If internal actuator harness requires replacement, notify SRA.

d.

Measure resistance from actuator harness connector pin 16 to all other pins in sensor harness connector. Resistance should be greater than 100k Ohms. (1) (2) If resistance is not as specified, repair or replace connectors (Volume 2, WP 0267). If internal actuator harness requires replacement, notify SRA.

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0007

ENGINE FUEL INJECTOR CIRCUITS TROUBLESHOOTING - Continued CORRECTIVE ACTION - Continued 3. Place ignition switch in OFF position and disconnect actuator harness from engine ECU. Remove rocker arm cover (WP 0057). Disconnect internal actuator harness from 15-pin connector. a. Inspect actuator harness connector, engine ECU connector, and 15-pin connector for dirty, corroded, bent, broken, pushed back, and extended pins. Clean and repair connector(s) as required (Volume 2, WP 0267). b. Check actuator harness connector, engine ECU connector, and 15-pin connector for dirt or moisture in or on connector and for missing or damaged connector seals. Remove dirt and moisture from connector. Replace missing or damaged connector seals (Volume 2, WP 0267). 4. Place ignition switch in OFF position and disconnect internal actuator harness from15-pin connector and from no. 3 injector solenoid. a. Measure resistance from 15-pin connector pin 5 to all other pins in connector. Resistance should be greater than 100k Ohms. (1) (2) b. If resistance is not as specified, repair or replace connectors (Volume 2, WP 0267). If internal actuator harness requires replacement, notify SRA.

Measure resistance from 15-pin connector pin 6 to all other pins in connector. Resistance should be greater than 100k Ohms. (1) (2) If resistance is not as specified, repair or replace connectors (Volume 2, WP 0267). If internal actuator harness requires replacement, notify SRA.

5. 6.

Place ignition switch in OFF position and, with rocker arm cover removed, disconnect internal actuator harness from injector solenoid. Measure resistance from injector solenoid pin A to pin B. Resistance should be 0.5 to1.5 Ohms. a. b. If resistance is as specified, replace engine ECU (WP 0100). If resistance is not as specified, replace injector (WP 0067).

7. 8.

Place ignition switch in OFF position and, with rocker arm cover removed, disconnect internal actuator harness from injector solenoid and remove injector solenoid wires from solenoid. Measure resistance from post to post on solenoid. Resistance should be 0.5 to 1.5 Ohms. If resistance is not as specified, replace injector (WP 0067).

0007-9

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0007

ENGINE FUEL INJECTOR CIRCUITS TROUBLESHOOTING - Continued

SYMPTOM

ERROR CODE 1314 MALFUNCTION Injector Circuit Failure. CORRECTIVE ACTION

WARNING

Injector solenoids receive high voltage when engine is operating. To avoid personal injury or death from electrical shock, do not wear jewelry or damp clothing, and do not touch injector solenoids or solenoid wires when engine is operating. 1. Place ignition switch in OFF position and disconnect actuator harness from engine ECU and from 15-pin connector at front of engine below rocker arm cover. a. Inspect actuator harness, actuator harness connector, and 15-pin connector for dirty, corroded, bent, broken, pushed back, and extended pins. Clean and repair connector(s) as required Electrical General Maintenance Instructions (Volume 2, WP 0267). b. Check actuator harness, actuator harness connector, and 15-pin connector for dirt or moisture in or on connector and for missing or damaged connector seals. Remove dirt and moisture from connector. Replace missing or damaged connector seals Electrical General Maintenance Instructions (Volume 2, WP 0267). 2. Place ignition switch in OFF position and disconnect actuator harness and sensor harness from engine ECU and actuator harness from 15-pin connector at front of engine below rocker arm cover. Perform the following resistance checks: a. Measure resistance from actuator harness connector pin 2 to all other pins in actuator harness connector. Resistance should be greater than 100k Ohms. (1) (2) b. If resistance is not as specified, repair or replace connectors Electrical General Maintenance Instructions (Volume 2, WP 0267). If internal actuator harness requires replacement, notify SRA.

Measure resistance from actuator harness connector pin 2 to all other pins in sensor harness connector. Resistance should be greater than 100k Ohms. (1) (2) If resistance is not as specified, repair or replace connectors Electrical General Maintenance Instructions (Volume 2, WP 0267). If internal actuator harness requires replacement, notify SRA.

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0007

ENGINE FUEL INJECTOR CIRCUITS TROUBLESHOOTING - Continued CORRECTIVE ACTION - Continued c. Measure resistance from actuator harness connector pin 1 to all other pins in actuator harness connector. Resistance should be greater than 100k Ohms. (1) (2) d. If resistance is not as specified, repair or replace connectors Electrical General Maintenance Instructions (Volume 2, WP 0267). If internal actuator harness requires replacement, notify SRA.

Measure resistance from actuator harness connector pin 1 to all other pins in sensor harness connector. Resistance should be greater than 100k Ohms. (1) (2) If resistance is not as specified, repair or replace connectors (Volume 2, WP 0267). If internal actuator harness requires replacement, notify SRA.

>100K OHMS

T0044JCH

Figure 4. Actuator Harness Test. 3. Place ignition switch in OFF position and disconnect actuator harness from engine ECU. Remove rocker arm cover (WP 0057). Disconnect internal actuator harness from 15-pin connector. a. Inspect actuator harness connector, engine ECU connector, and 15-pin connector for dirty, corroded, bent, broken, pushed back, and extended pins. Clean and repair connector(s) as required (Volume 2, WP 0267). b. Check actuator harness connector, engine ECU connector, and 15-pin connector for dirt or moisture in or on connector and for missing or damaged connector seals. Remove dirt and moisture from connector. Replace missing or damaged connector seals (Volume 2, WP 0267). 4. Place ignition switch in OFF position and disconnect internal actuator harness from 15-pin connector and from no. 6 injector solenoid. a. Measure resistance from 15-pin connector pin 5 to all other pins in connector. Resistance should be greater than 100k Ohms. (1) If resistance is not as specified, repair or replace connectors (Volume 2, WP 0267).

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0007

ENGINE FUEL INJECTOR CIRCUITS TROUBLESHOOTING - Continued CORRECTIVE ACTION - Continued (2) b. If internal actuator harness requires replacement, notify SRA.

Measure resistance from 15-pin connector pin 11 to all other pins in connector. Resistance should be greater than 100k Ohms. (1) (2) If resistance is not as specified, repair or replace connectors (Volume 2, WP 0267). If internal actuator harness requires replacement, notify SRA.

c.

Measure resistance from 15-pin connector pin 12 to all other pins in connector. Resistance should be greater than 100k Ohms. (1) (2) If resistance is not as specified, repair or replace connectors (Volume 2, WP 0267). If internal actuator harness requires replacement, notify SRA.

5. 6.

Place ignition switch in OFF position and, with rocker arm cover removed, disconnect internal actuator harness from injector solenoid. Measure resistance from injector solenoid pin A to pin B. Resistance should be 0.5 to1.5 Ohms. a. b. If resistance is as specified, replace engine ECU (WP 0100). If resistance is not as specified, replace injector (WP 0067).

7. 8.

Place ignition switch in OFF position and, with rocker arm cover removed, disconnect internal actuator harness from injector solenoid and remove injector solenoid wires from solenoid. Measure resistance from post to post on solenoid. Resistance should be 0.5 to 1.5 Ohms. If resistance is not as specified, replace injector (WP 0067).

SYMPTOM

ERROR CODE 1315 MALFUNCTION Injector Circuit Failure. CORRECTIVE ACTION

WARNING

Injector solenoids receive high voltage when engine is operating. To avoid personal injury or death from electrical shock, do not wear jewelry or damp clothing, and do not touch injector solenoids or solenoid wires when engine is operating. 1. Place ignition switch in OFF position and disconnect actuator harness from engine ECU and from 15-pin connector at front of engine below rocker arm cover.

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0007

ENGINE FUEL INJECTOR CIRCUITS TROUBLESHOOTING - Continued CORRECTIVE ACTION - Continued a. Inspect actuator harness, actuator harness connector, and 15-pin connector for dirty, corroded, bent, broken, pushed back, and extended pins. Clean and repair connector(s) as required (Volume 2, WP 0267). b. Check actuator harness, actuator harness connector, and 15-pin connector for dirt or moisture in or on connector and for missing or damaged connector seals. Remove dirt and moisture from connector. Replace missing or damaged connector seals (Volume 2, WP 0267). 2. Place ignition switch in OFF position and disconnect actuator harness and sensor harness from engine ECU and actuator harness from 15-pin connector at front of engine below rocker arm cover. Perform the following resistance checks: a. Measure resistance from actuator harness connector pin 7 to all other pins in actuator harness connector. Resistance should be greater than 100k Ohms. (1) (2) If resistance is not as specified, repair or replace connectors (Volume 2, WP 0267). If internal actuator harness requires replacement, notify SRA.

>100K OHMS

T0045JCH

Figure 5. Actuator Harness Test. b. Measure resistance from actuator harness connector pin 7 to all other pins in sensor harness connector. Resistance should be greater than 100k Ohms. (1) (2) If resistance is not as specified, repair or replace connectors (Volume 2, WP 0267). If internal actuator harness requires replacement, notify SRA.

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0007

ENGINE FUEL INJECTOR CIRCUITS TROUBLESHOOTING - Continued CORRECTIVE ACTION - Continued c. Measure resistance from actuator harness connector pin 8 to all other pins in actuator harness connector. Resistance should be greater than 100k Ohms. (1) (2) d. If resistance is not as specified, repair or replace connectors (Volume 2, WP 0267). If internal actuator harness requires replacement, notify SRA.

Measure resistance from actuator harness connector pin 8 to all other pins in sensor harness connector. Resistance should be greater than 100k Ohms. (1) (2) If resistance is not as specified, repair or replace connectors (Volume 2, WP 0267). If internal actuator harness requires replacement, notify SRA.

3.

Place ignition switch in OFF position and disconnect actuator harness from engine ECU. Remove rocker arm cover (WP 0057). Disconnect internal actuator harness from 15-pin connector. a. Inspect actuator harness connector, engine ECU connector, and 15-pin connector for dirty, corroded, bent, broken, pushed back, and extended pins. Clean and repair connector(s) as required (Volume 2, WP 0267). b. Check actuator harness connector, engine ECU connector, and 15-pin connector for dirt or moisture in or on connector and for missing or damaged connector seals. Remove dirt and moisture from connector. Replace missing or damaged connector seals Electrical General Maintenance Instructions (Volume 2, WP 0267).

4.

Place ignition switch in OFF position and disconnect internal actuator harness from 15-pin connector and from no. 2 injector solenoid. a. Measure resistance from 15-pin connector pin 3 to all other pins in connector. Resistance should be greater than 100k Ohms. (1) (2) b. If resistance is not as specified, repair or replace connectors (Volume 2, WP 0267). If internal actuator harness requires replacement, notify SRA.

Measure resistance from 15-pin connector pin 4 to all other pins in connector. Resistance should be greater than 100k Ohms. (1) (2) If resistance is not as specified, repair or replace connectors (Volume 2, WP 0267). If internal actuator harness requires replacement, notify SRA.

5. 6.

Place ignition switch in OFF position and, with rocker arm cover removed, disconnect internal actuator harness from injector solenoid. Measure resistance from injector solenoid pin A to pin B. Resistance should be 0.5 to 1.5 Ohms. a. b. If resistance is as specified, replace engine ECU (WP 0100). If resistance is not as specified, replace injector (WP 0067).

7. 8.

Place ignition switch in OFF position and, with rocker arm cover removed, disconnect internal actuator harness from injector solenoid and remove injector solenoid wires from solenoid. Measure resistance from post to post on solenoid. Resistance should be 0.5 to 1.5 Ohms. If resistance is not as specified, replace injector (WP 0067).

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0007

ENGINE FUEL INJECTOR CIRCUITS TROUBLESHOOTING - Continued

SYMPTOM

ERROR CODE 1321 MALFUNCTION Injector Circuit Failure. CORRECTIVE ACTION

WARNING

Injector solenoids receive high voltage when engine is operating. To avoid personal injury or death from electrical shock, do not wear jewelry or damp clothing, and do not touch injector solenoids or solenoid wires when engine is operating. 1. Place ignition switch in OFF position and disconnect actuator harness from engine ECU and from 15-pin connector at front of engine below rocker arm cover. a. Inspect actuator harness, actuator harness connector, and 15-pin connector for dirty, corroded, bent, broken, pushed back, and extended pins. Clean and repair connector(s) as required (Volume 2, WP 0267). b. Check actuator harness, actuator harness connector, and 15-pin connector for dirt or moisture in or on connector and for missing or damaged connector seals. Remove dirt and moisture from connector. Replace missing or damaged connector seals (Volume 2, WP 0267). 2. Place ignition switch in OFF position and disconnect actuator harness and sensor harness from engine ECU and actuator harness from 15-pin connector at front of engine below rocker arm cover. Perform the following resistance checks: a. Measure resistance from actuator harness connector pin 26 to all other pins in actuator harness connector. Resistance should be greater than 100k Ohms. (1) (2) b. If resistance is not as specified, repair or replace connectors (Volume 2, WP 0267). If internal actuator harness requires replacement, notify SRA.

Measure resistance from actuator harness connector pin 26 to all other pins in sensor harness connector. Resistance should be greater than 100k Ohms. (1) (2) If resistance is not as specified, repair or replace connectors (Volume 2, WP 0267). If internal actuator harness requires replacement, notify SRA.

c.

Measure resistance from actuator harness connector pin 36 to all other pins in actuator harness connector. Resistance should be greater than 100k Ohms. (1) If resistance is not as specified, repair or replace connectors (Volume 2, WP 0267).

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0007

ENGINE FUEL INJECTOR CIRCUITS TROUBLESHOOTING - Continued CORRECTIVE ACTION - Continued (2) d. If internal actuator harness requires replacement, notify SRA.

Measure resistance from actuator harness connector pin 36 to all other pins in sensor harness connector. Resistance should be greater than 100k Ohms. (1) (2) If resistance is not as specified, repair or replace connectors (Volume 2, WP 0267). If internal actuator harness requires replacement, notify SRA.

>100K OHMS

T0056JCH

Figure 6. Actuator Harness Test. 3. Place ignition switch in OFF position and disconnect actuator harness from engine ECU. Remove rocker arm cover (WP 0057). Disconnect internal actuator harness from 15-pin connector. a. Inspect actuator harness connector, engine ECU connector, and 15-pin connector for dirty, corroded, bent, broken, pushed back, and extended pins. Clean and repair connector(s) as required (Volume 2, WP 0267). b. Check actuator harness connector, engine ECU connector, and 15-pin connector for dirt or moisture in or on connector and for missing or damaged connector seals. Remove dirt and moisture from connector. Replace missing or damaged connector seals (Volume 2, WP 0267). 4. Place ignition switch in OFF position and disconnect internal actuator harness from 15-pin connector and from no. 4 injector solenoid. a. Measure resistance from 15-pin connector pin 7 to all other pins in connector. Resistance should be greater than 100k Ohms. (1) (2) b. If resistance is not as specified, repair or replace connectors (Volume 2, WP 0267). If internal actuator harness requires replacement, notify SRA.

Measure resistance from 15-pin connector pin 8 to all other pins in connector. Resistance should be greater than 100k Ohms. (1) If resistance is not as specified, repair or replace connectors (Volume 2, WP 0267).

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0007

ENGINE FUEL INJECTOR CIRCUITS TROUBLESHOOTING - Continued CORRECTIVE ACTION - Continued (2) 5. 6. If internal actuator harness requires replacement, notify SRA.

Place ignition switch in OFF position and, with rocker arm cover removed, disconnect internal actuator harness from injector solenoid. Measure resistance from injector solenoid pin A to pin B. Resistance should be 0.5 to 1.5 Ohms. a. b. If resistance is as specified, replace engine ECU (WP 0099). If resistance is not as specified, replace injector (WP 0067).

7. 8.

Place ignition switch in OFF position and, with rocker arm cover removed, disconnect internal actuator harness from injector solenoid and remove injector solenoid wires from solenoid. Measure resistance from post to post on solenoid. Resistance should be 0.5 to 1.5 Ohms. If resistance is not as specified, replace injector (WP 0067).

SYMPTOM

ERROR CODE 1322 MALFUNCTION Injector Circuit Failure. CORRECTIVE ACTION

WARNING

Injector solenoids receive high voltage when engine is operating. To avoid personal injury or death from electrical shock, do not wear jewelry or damp clothing, and do not touch injector solenoids or solenoid wires when engine is operating. 1. Place ignition switch in OFF position and disconnect actuator harness from engine ECU. a. Inspect actuator harness and ECU connector for dirty, corroded, bent, broken, pushed back, and extended pins. Clean and repair connector(s) as required (Volume 2, WP 0267). b. Check actuator harness and ECU connector for dirt or moisture in or on connector and for missing or damaged connector seals. Remove dirt and moisture from connector. Replace missing or damaged connector seals (Volume 2, WP 0267).

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TM 10-3930-675-23-1

0007

ENGINE FUEL INJECTOR CIRCUITS TROUBLESHOOTING - Continued CORRECTIVE ACTION - Continued 2. Place ignition switch in OFF position and disconnect actuator harness from engine ECU and 15pin connector at front of engine below rocker arm cover. Install jumper wire from pin 1 to pin 2 at 15-pin connector, actuator harness side. Measure resistance from actuator harness connector pin 9 to actuator harness connector pin 10. Resistance should be less than 10 Ohms. (1) (2) If resistance is not as specified, repair or replace connectors (Volume 2, WP 0267). If engine harness requires replacement, notify SRA.

<10 OHMS

T0047JCH

Figure 7. Actuator Harness Test. 3. Place ignition switch in OFF position and disconnect actuator harness from engine ECU and 15-pin connector at front of engine below rocker arm cover. Disconnect sensor harness from ECU engine. a. Measure resistance from actuator harness connector pin 9 to all pins in actuator harness connector. Resistance should be greater than 100k Ohms. (1) (2) b. If resistance is not as specified, repair or replace connectors (Volume 2, WP 0267). If engine harness requires replacement, notify SRA.

Measure resistance from actuator harness connector pin 9 to all pins in sensor harness connector. Resistance should be greater than 100k Ohms. (1) (2) If resistance is not as specified, repair or replace connectors (Volume 2, WP 0267). If engine harness requires replacement, notify SRA.

c.

Measure resistance from actuator harness connector pin 10 to all pins in actuator harness connector. Resistance should be greater than 100k Ohms. (1) (2) If resistance is not as specified, repair or replace connectors (Volume 2, WP 0267). If engine harness requires replacement, notify SRA.

0007-18

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0007

ENGINE FUEL INJECTOR CIRCUITS TROUBLESHOOTING - Continued CORRECTIVE ACTION - Continued

>100K OHMS

>100K OHMS

T0048JCH

Figure 8. Actuator Harness Test. d. Measure resistance from actuator harness connector pin 10 to all pins in sensor harness connector. Resistance should be greater than 100k Ohms. (1) (2) If resistance is not as specified, repair or replace connectors (Volume 2, WP 0267). If engine harness requires replacement, notify SRA.

0007-19

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TM 10-3930-675-23-1

0007

ENGINE FUEL INJECTOR CIRCUITS TROUBLESHOOTING - Continued CORRECTIVE ACTION - Continued 4. Place ignition switch in OFF position and disconnect actuator harness 15-pin connector at front of engine below rocker arm cover. Disconnect actuator harness connector from engine ECU. a. Measure resistance from actuator harness connector pin 9 to engine block ground. Resistance should be greater than 100k Ohms. (1) (2) b. If resistance is not as specified, repair or replace connectors (Volume 2, WP 0267). If engine harness requires replacement, notify SRA.

Measure resistance from actuator harness connector pin 10 to engine block ground. Resistance should be greater than 100k Ohms. (1) (2) If resistance is not as specified, repair or replace connectors (Volume 2, WP 0267). If engine harness requires replacement, notify SRA.

>100K OHMS

T0049JCH

Figure 9. Actuator Harness Test. 5. Place ignition switch in OFF position. Remove rocker arm cover (WP 0057). Disconnect injector solenoid connector from no. 1 injector solenoid and internal actuator harness from 15-pin connector. a. Inspect internal actuator harness and injector solenoid connector for dirty, corroded, bent, broken, pushed back, and extended pins. Clean and repair connector(s) as required (Volume 2, WP 0267). b. Check internal actuator harness and injector solenoid connector for dirt or moisture in or on connector and for missing or damaged connector seals. Remove dirt and moisture from connector. Replace missing or damaged connector seals (Volume 2, WP 0267). 6. Place ignition switch in OFF position and, with rocker arm cover removed, disconnect actuator harness from 15-pin connector and injector solenoid wires from no. 1 injector solenoid.

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0007

ENGINE FUEL INJECTOR CIRCUITS TROUBLESHOOTING - Continued CORRECTIVE ACTION - Continued a. Measure resistance from 15-pin connector pin 1 (or A) to each injector pigtail nut that connects the no. 1 injector (resistance to one of these nuts must be within specifications). Resistance should be less than 10 Ohms. (1) (2) b. If resistance is not as specified, repair or replace connectors (WP 0100). If internal actuator harness requires replacement, notify SRA.

Measure resistance from 15-pin connector pin 2 (or B) to each injector pigtail nut that connects the no. 1 injector (resistance to one of these nuts must be within specifications). Resistance should be less than 10 Ohms. If resistance is not as specified, notify SRA to replace internal actuator harness.

<10 OHMS

T0050JCH

Figure 10. 15-Pin Connector Test. 7. Place ignition switch in OFF position and disconnect internal actuator harness from injector solenoid connector and disconnect injector solenoid wires from solenoid. a. Measure resistance from pin A (or 1) of injector solenoid connector to injector wire pigtail nut. Resistance should be less than 10 Ohms. (1) (2) b. If resistance is as specified, notify SRA to replace internal actuator harness. If resistance is not as specified, replace injector solenoid wires.

Measure resistance from pin B (or 2) of injector solenoid connector to injector wire pigtail nut. Resistance should be less than 10 Ohms. (1) (2) If resistance is as specified, notify SRA to replace internal actuator harness. If resistance is not as specified, replace injector solenoid wires.

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0007

ENGINE FUEL INJECTOR CIRCUITS TROUBLESHOOTING - Continued CORRECTIVE ACTION - Continued 8. Place ignition switch in OFF position and, with rocker arm cover removed, disconnect internal actuator harness from 15-pin connector. a. Measure resistance from pin 1 (or A) on internal harness side of actuator harness 15-pin connector to all other pins in connector. Resistance should be greater than 100k Ohms. If resistance is not as specified, notify SRA to replace internal actuator harness. b. Measure resistance from pin 2 (or B) on internal harness side of actuator harness 15-pin connector to all other pins in connector. Resistance should be greater than 100k Ohms. If resistance is not as specified, notify SRA to replace internal actuator harness.

>100K OHMS

>100K OHMS

T0051JCH

Figure 11. 15-Pin Connector Test. 9. Place ignition switch in OFF position and, with rocker arm cover removed, disconnect injector solenoid connector on internal actuator harness from no. 1 injector solenoid. a. Measure resistance from pin 1 (or A) on solenoid connector to engine block ground. Resistance should be greater than 100k Ohms. If resistance is not as specified, notify SRA to replace internal actuator harness. b. Measure resistance from pin 2 (or B) on solenoid connector to engine block ground. Resistance should be greater than 100k Ohms. If resistance is not as specified, notify SRA to replace internal actuator harness.

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0007

ENGINE FUEL INJECTOR CIRCUITS TROUBLESHOOTING - Continued CORRECTIVE ACTION - Continued

>100K OHMS

T0052JCH

Figure 12. Solenoid Connector Test. 10. 11. Place ignition switch in OFF position and, with rocker arm cover removed, disconnect no.1 injector solenoid from internal actuator harness. Measure resistance from post to post on solenoid. Resistance should be 0.5 to 1.5 Ohms. a. b. SYMPTOM If resistance is as specified, replace engine ECU (WP 0100). If resistance is not as specified, replace injector (WP 0067).

ERROR CODE 1323 MALFUNCTION Injector Circuit Failure. CORRECTIVE ACTION

WARNING

Injector solenoids receive high voltage when engine is operating. To avoid personal injury or death from electrical shock, do not wear jewelry or damp clothing, and do not touch injector solenoids or solenoid wires when engine is operating. 1. Place ignition switch in OFF position and disconnect actuator harness from engine ECU.

0007-23

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TM 10-3930-675-23-1

0007

ENGINE FUEL INJECTOR CIRCUITS TROUBLESHOOTING - Continued CORRECTIVE ACTION - Continued a. Inspect actuator harness and ECU connector for dirty, corroded, bent, broken, pushed back, and extended pins. Clean and repair connector(s) as required (Volume 2, WP 0267). b. Check actuator harness and ECU connector for dirt or moisture in or on connector and for missing or damaged connector seals. Remove dirt and moisture from connector. Replace missing or damaged connector seals (Volume 2, WP 0267). 2. Place ignition switch in OFF position and disconnect actuator harness from engine ECU and 15-pin connector at front of engine below rocker arm cover. Install jumper wire from pin 9 to pin 10 at 15-pin connector, actuator harness side. Measure resistance from actuator harness connector pin 3 to pin 4. Resistance should be less than 10 Ohms. a. b. If resistance is not as specified, repair or replace connectors (Volume 2, WP 0267). If engine harness requires replacement, notify SRA.

3.

<10 OHMS

T0053JCH

Figure 13. Actuator Harness Test. 4. Place ignition switch in OFF position and disconnect actuator harness from engine ECU and 15-pin connector at front of engine below rocker arm cover. Disconnect sensor harness from engine ECU. a. Measure resistance from actuator harness connector pin 3 to all pins in actuator harness connector. Resistance should be greater than 100k Ohms. (1) (2) b. If resistance is not as specified, repair or replace connectors (Volume 2, WP 0267). If engine harness requires replacement, notify SRA.

Measure resistance from actuator harness connector pin 3 to all pins in sensor harness connector. Resistance should be greater than 100k Ohms.

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0007

ENGINE FUEL INJECTOR CIRCUITS TROUBLESHOOTING - Continued CORRECTIVE ACTION - Continued (1) (2) c. If resistance is not as specified, repair or replace connectors (Volume 2, WP 0267). If engine harness requires replacement, notify SRA.

Measure resistance from actuator harness connector pin 4 to all pins in actuator harness connector. Resistance should be greater than 100k Ohms. (1) (2) If resistance is not as specified, repair or replace connectors (Volume 2, WP 0267). If engine harness requires replacement, notify SRA.

d.

Measure resistance from actuator harness connector pin 4 to all pins in sensor harness connector. Resistance should be greater than 100k Ohms. (1) (2) If resistance is not as specified, repair or replace connectors (Volume 2, WP 0267). If engine harness requires replacement, notify SRA.

>100K OHMS
T0042JCH

Figure 14. Actuator Harness Connector Test.

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0007

ENGINE FUEL INJECTOR CIRCUITS TROUBLESHOOTING - Continued CORRECTIVE ACTION - Continued 5. Place ignition switch in OFF position and disconnect actuator harness 15-pin connector at front of engine below rocker arm cover. Disconnect actuator harness connector from engine ECU. a. Measure resistance from actuator harness connector pin 3 to engine block ground. Resistance should be greater than 100k Ohms. (1) (2) b. If resistance is not as specified, repair or replace connectors (Volume 2, WP 0267). If engine harness requires replacement, notify SRA.

Measure resistance from actuator harness connector pin 4 to engine block ground. Resistance should be greater than 100k Ohms. (1) (2) If resistance is not as specified, repair or replace connectors (Volume 2, WP 0267). If engine harness requires replacement, notify SRA.

>100K OHMS

T0054JCH

Figure 15. Actuator Harness Connector Test. 6. Place ignition switch in OFF position. Remove rocker arm cover (WP 0057). Disconnect injector solenoid connector from no. 5 injector solenoid and internal actuator harness from 15-pin connector. a. Inspect internal actuator harness and injector solenoid connector for dirty, corroded, bent, broken, pushed back, and extended pins. Clean and repair connector(s) as required (Volume 2, WP 0267). b. Check internal actuator harness and injector solenoid connector for dirt or moisture in or on connector and for missing or damaged connector seals. Remove dirt and moisture from connector. Replace missing or damaged connector seals (Volume 2, WP 0267). 7. Place ignition switch in OFF position and, with rocker arm cover removed, disconnect actuator harness from 15-pin connector and injector solenoid wires from no. 5 injector solenoid.

0007-26

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0007

ENGINE FUEL INJECTOR CIRCUITS TROUBLESHOOTING - Continued CORRECTIVE ACTION - Continued a. Measure resistance from 15-pin connector pin 1 (or A) to each injector pigtail nut that connects the no. 1 injector (resistance to one of these nuts must be within specifications). Resistance should be less than 10 Ohms. (1) (2) b. If resistance is not as specified, repair or replace connectors (Volume 2, WP 0267). If internal actuator harness requires replacement, notify SRA.

Measure resistance from 15-pin connector pin 2 (or B) to each injector pigtail nut that connects the no. 1 injector (resistance to one of these nuts must be within specifications). Resistance should be less than 10 Ohms. If resistance is not as specified, notify SRA to replace internal actuator harness.

<10 OHMS

T0055JCH

Figure 16. Injector Wiring Test. 8. Place ignition switch in OFF position and disconnect internal actuator harness from injector solenoid connector and disconnect injector solenoid wires from solenoid. a. Measure resistance from pin A (or 1) of injector solenoid connector to injector wire pigtail nut. Resistance should be less than 10 Ohms. (1) (2) b. If resistance is as specified, notify SRA to replace internal actuator harness. If resistance is not as specified, replace injector solenoid wires.

Measure resistance from pin B (or 2) of injector solenoid connector to injector wire pigtail nut. Resistance should be less than 10 Ohms. (1) (2) If resistance is as specified, notify SRA to replace internal actuator harness. If resistance is not as specified, replace injector solenoid wires.

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0007

ENGINE FUEL INJECTOR CIRCUITS TROUBLESHOOTING - Continued CORRECTIVE ACTION - Continued 9. Place ignition switch in OFF position and, with rocker arm cover removed, disconnect internal actuator harness from 15-pin connector. a. Measure resistance from pin 1 (or A) on internal harness side of actuator harness 15-pin connector to all other pins in connector. Resistance should be greater than 100k Ohms. If resistance is not as specified, notify SRA to replace internal actuator harness. b. Measure resistance from pin 2 (or B) on internal harness side of actuator harness 15-pin connector to all other pins in connector. Resistance should be greater than 100k Ohms. If resistance is not as specified, notify SRA to replace internal actuator harness.

>100K OHMS

T0056JCH

Figure 17. Actuator Harness Test. 10. Place ignition switch in OFF position and, with rocker arm cover removed, disconnect injector solenoid connector on internal actuator harness from no. 5 injector solenoid. a. Measure resistance from pin 1 (or A) on solenoid connector to engine block ground. Resistance should be greater than 100k Ohms. If resistance is not as specified, notify SRA to replace internal actuator harness. b. Measure resistance from pin 2 (or B) on solenoid connector to engine block ground. Resistance should be greater than 100k Ohms. If resistance is not as specified, notify SRA to replace internal actuator harness.

0007-28

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0007

ENGINE FUEL INJECTOR CIRCUITS TROUBLESHOOTING - Continued CORRECTIVE ACTION - Continued

>100K OHMS

T0057JCH

Figure 18. Solenoid Connector Test. 11. 12. Place ignition switch in OFF position and, with rocker arm cover removed, disconnect no.5 injector solenoid from internal actuator harness. Measure resistance from post to post on solenoid. Resistance should be 0.5 to 1.5 Ohms. a. b. SYMPTOM If resistance is as specified, replace engine ECU (WP 0100). If resistance is not as specified, replace injector (WP 0067).

ERROR CODE 1324 MALFUNCTION Injector Circuit Failure. CORRECTIVE ACTION

WARNING

Injector solenoids receive high voltage when engine is operating. To avoid personal injury or death from electrical shock, do not wear jewelry or damp clothing, and do not touch injector solenoids or solenoid wires when engine is operating. 1. Place ignition switch in OFF position and disconnect actuator harness from engine ECU.

0007-29

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0007

ENGINE FUEL INJECTOR CIRCUITS TROUBLESHOOTING - Continued CORRECTIVE ACTION - Continued a. Inspect actuator harness and ECU connector for dirty, corroded, bent, broken, pushed back, and extended pins. Clean and repair connector(s) as required (Volume 2, WP 0267). b. Check actuator harness and ECU connector for dirt or moisture in or on connector and for missing or damaged connector seals. Remove dirt and moisture from connector. Replace missing or damaged connector seals (Volume 2, WP 0267). 2. Place ignition switch in OFF position and disconnect actuator harness from engine ECU and 15-pin connector at front of engine below rocker arm cover. Install jumper wire from pin 5 to pin 6 at 15-pin connector, actuator harness side. Measure resistance from actuator harness connector pin 6 to pin 16. Resistance should be less than 10 Ohms. a. b. If resistance is not as specified, repair or replace connectors (Volume 2, WP 0267). If engine harness requires replacement, notify SRA.

3.

<10 OHMS

T0058JCH

Figure 19. Actuator Harness Test. 4. Place ignition switch in OFF position and disconnect actuator harness from engine ECU and 15-pin connector at front of engine below rocker arm cover. Disconnect sensor harness from engine ECU. a. Measure resistance from actuator harness connector pin 6 to all pins in actuator harness connector. Resistance should be greater than 100k Ohms. (1) (2) b. If resistance is not as specified, repair or replace connectors (Volume 2, WP 0267). If engine harness requires replacement, notify SRA.

Measure resistance from actuator harness connector pin 6 to all pins in sensor harness connector. Resistance should be greater than 100k Ohms.

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0007

ENGINE FUEL INJECTOR CIRCUITS TROUBLESHOOTING - Continued CORRECTIVE ACTION - Continued (1) (2) c. If resistance is not as specified, repair or replace connectors (Volume 2, WP 0267). If engine harness requires replacement, notify SRA.

Measure resistance from actuator harness connector pin 16 to all pins in actuator harness connector. Resistance should be greater than 100k Ohms. (1) (2) If resistance is not as specified, repair or replace connectors (Volume 2, WP 0267). If engine harness requires replacement, notify SRA.

d.

Measure resistance from actuator harness connector pin 16 to all pins in sensor harness connector. Resistance should be greater than 100k Ohms. (1) (2) If resistance is not as specified, repair or replace connectors (Volume 2, WP 0267). If engine harness requires replacement, notify SRA.

>100K OHMS

T0059JCH

Figure 20. Actuator Harness Test. 5. Place ignition switch in OFF position and disconnect actuator harness 15-pin connector at front of engine below rocker arm cover. Disconnect actuator harness connector from engine ECU. a. Measure resistance from actuator harness connector pin 6 to engine block ground. Resistance should be greater than 100k Ohms. (1) (2) If resistance is not as specified, repair or replace connectors (Volume 2, WP 0267). If engine harness requires replacement, notify SRA.

0007-31

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0007

ENGINE FUEL INJECTOR CIRCUITS TROUBLESHOOTING - Continued CORRECTIVE ACTION - Continued b. Measure resistance from actuator harness connector pin 16 to engine block ground. Resistance should be greater than 100k Ohms. (1) (2) If resistance is not as specified, repair or replace connectors (Volume 2, WP 0267). If engine harness requires replacement, notify SRA.

>100K OHMS

T0043JCH

Figure 21. Actuator Harness Test. 6. Place ignition switch in OFF position. Remove rocker arm cover (WP 0057). Disconnect injector solenoid connector from no. 3 injector solenoid and internal actuator harness from 15-pin connector. a. Inspect internal actuator harness and injector solenoid connector for dirty, corroded, bent, broken, pushed back, and extended pins. Clean and repair connector(s) as required (Volume 2, WP 0267). b. Check internal actuator harness and injector solenoid connector for dirt or moisture in or on connector and for missing or damaged connector seals. Remove dirt and moisture from connector. Replace missing or damaged connector seals (Volume 2, WP 0267). 7. Place ignition switch in OFF position and, with rocker arm cover removed, disconnect actuator harness from 15-pin connector and injector solenoid wires from no. 3 injector solenoid. a. Measure resistance from 15-pin connector pin 1 (or A) to each injector pigtail nut that connects the no. 1 injector (resistance to one of these nuts must be within specifications). Resistance should be less than 10 Ohms. (1) (2) If resistance is not as specified, repair or replace connectors (Volume 2, WP 0267). If internal actuator harness requires replacement, notify SRA.

0007-32

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0007

ENGINE FUEL INJECTOR CIRCUITS TROUBLESHOOTING - Continued CORRECTIVE ACTION - Continued b. Measure resistance from 15-pin connector pin 2 (or B) to each injector pigtail nut that connects the no. 1 injector (resistance to one of these nuts must be within specifications). Resistance should be less than 10 Ohms. If resistance is not as specified, notify SRA to replace internal actuator harness.

<10 OHMS

T0055JCH

Figure 22. Injector Wiring Test. 8. Place ignition switch in OFF position and disconnect internal actuator harness from injector solenoid connector and disconnect injector solenoid wires from solenoid. a. Measure resistance from pin A (or 1) of injector solenoid connector to injector wire pigtail nut. Resistance should be less than 10 Ohms. (1) (2) b. If resistance is as specified, notify SRA to replace internal actuator harness. If resistance is not as specified, replace injector solenoid wires.

Measure resistance from pin B (or 2) of injector solenoid connector to injector wire pigtail nut. Resistance should be less than 10 Ohms. (1) (2) If resistance is as specified, notify SRA to replace internal actuator harness. If resistance is not as specified, replace injector solenoid wires.

0007-33

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0007

ENGINE FUEL INJECTOR CIRCUITS TROUBLESHOOTING - Continued CORRECTIVE ACTION - Continued 9. Place ignition switch in OFF position and, with rocker arm cover removed, disconnect internal actuator harness from 15-pin connector. a. Measure resistance from pin 1 (or A) on internal harness side of actuator harness 15-pin connector to all other pins in connector. Resistance should be greater than 100k Ohms. If resistance is not as specified, notify SRA to replace internal actuator harness. b. Measure resistance from pin 2 (or B) on internal harness side of actuator harness 15-pin connector to all other pins in connector. Resistance should be greater than 100k Ohms. If resistance is not as specified, notify SRA to replace internal actuator harness.

>100K OHMS

T0056JCH

Figure 23. Injector Wiring Test. 10. Place ignition switch in OFF position and, with rocker arm cover removed, disconnect injector solenoid connector on internal actuator harness from no. 3 injector solenoid. a. Measure resistance from pin 1 (or A) on solenoid connector to engine block ground. Resistance should be greater than 100k Ohms. If resistance is not as specified, notify SRA to replace internal actuator harness. b. Measure resistance from pin 2 (or B) on solenoid connector to engine block ground. Resistance should be greater than 100k Ohms. If resistance is not as specified, notify SRA to replace internal actuator harness.

0007-34

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0007

ENGINE FUEL INJECTOR CIRCUITS TROUBLESHOOTING - Continued CORRECTIVE ACTION - Continued

>100K OHMS

T0057JCH

Figure 24. Injector Wiring Test. 11. 12. Place ignition switch in OFF position and, with rocker arm cover removed, disconnect no. 3 injector solenoid from internal actuator harness. Measure resistance from post to post on solenoid. Resistance should be 0.5 to 1.5 Ohms. a. b. SYMPTOM If resistance is as specified, replace engine ECU (WP 0100). If resistance is not as specified, replace injector (WP 0067).

ERROR CODE 1325 MALFUNCTION Injector Circuit Failure. CORRECTIVE ACTION

WARNING

Injector solenoids receive high voltage when engine is operating. To avoid personal injury or death from electrical shock, do not wear jewelry or damp clothing, and do not touch injector solenoids or solenoid wires when engine is operating. 1. Place ignition switch in OFF position and disconnect actuator harness from engine ECU.

0007-35

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0007

ENGINE FUEL INJECTOR CIRCUITS TROUBLESHOOTING - Continued CORRECTIVE ACTION - Continued a. Inspect actuator harness and ECU connector for dirty, corroded, bent, broken, pushed back, and extended pins. Clean and repair connector(s) as required (Volume 2, WP 0267). b. Check actuator harness and ECU connector for dirt or moisture in or on connector and for missing or damaged connector seals. Remove dirt and moisture from connector. Replace missing or damaged connector seals (Volume 2, WP 0267). 2. Place ignition switch in OFF position and disconnect actuator harness from engine ECU and 15-pin connector at front of engine below rocker arm cover. Install jumper wire from pin 11 to pin 12 at 15-pin connector, actuator harness side. Measure resistance from actuator harness connector pin 1 to pin 2. Resistance should be less than 10 Ohms. a. b. If resistance is not as specified, repair or replace connectors (Volume 2, WP 0267). If engine harness requires replacement, notify SRA.

3.

<10 OHMS

T0058JCH

Figure 25. Actuator Harness Test. 4. Place ignition switch in OFF position and disconnect actuator harness from engine ECU and 15-pin connector at front of engine below rocker arm cover. Disconnect sensor harness from engine ECU. a. Measure resistance from actuator harness connector pin 1 to all pins in actuator harness connector. Resistance should be greater than 100k Ohms. (1) (2) b. If resistance is not as specified, repair or replace connectors (Volume 2, WP 0267). If engine harness requires replacement, notify SRA.

Measure resistance from actuator harness connector pin 1 to all pins in sensor harness connector. Resistance should be greater than 100k Ohms.

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0007

ENGINE FUEL INJECTOR CIRCUITS TROUBLESHOOTING - Continued CORRECTIVE ACTION - Continued (1) (2) c. If resistance is not as specified, repair or replace connectors (Volume 2, WP 0267). If engine harness requires replacement, notify SRA.

Measure resistance from actuator harness connector pin 2 to all pins in actuator harness connector. Resistance should be greater than 100k Ohms. (1) (2) If resistance is not as specified, repair or replace connectors (Volume 2, WP 0267). If engine harness requires replacement, notify SRA.

d.

Measure resistance from actuator harness connector pin 2 to all pins in sensor harness connector. Resistance should be greater than 100k Ohms. (1) (2) If resistance is not as specified, repair or replace connectors (Volume 2, WP 0267). If engine harness requires replacement, notify SRA.

>100K OHMS

T0059JCH

Figure 26. Actuator Harness Test. 5. Place ignition switch in OFF position and disconnect actuator harness 15-pin connector at front of engine below rocker arm cover. Disconnect actuator harness connector from engine ECU. a. Measure resistance from actuator harness connector pin 1 to engine block ground. Resistance should be greater than 100k Ohms. (1) (2) If resistance is not as specified, repair or replace connectors (Volume 2, WP 0267). If engine harness requires replacement, notify SRA.

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0007

ENGINE FUEL INJECTOR CIRCUITS TROUBLESHOOTING - Continued CORRECTIVE ACTION - Continued b. Measure resistance from actuator harness connector pin 2 to engine block ground. Resistance should be greater than 100k Ohms. (1) (2) If resistance is not as specified, repair or replace connectors (Volume 2, WP 0267). If engine harness requires replacement, notify SRA.

>100K OHMS

T0060JCH

Figure 27. Actuator Harness Test. 6. Place ignition switch in OFF position. Remove rocker arm cover (WP 0057)). Disconnect injector solenoid connector from no. 6 injector solenoid and internal actuator harness from 15-pin connector. a. Inspect internal actuator harness and injector solenoid connector for dirty, corroded, bent, broken, pushed back, and extended pins. Clean and repair connector(s) as required (Volume 2, WP 0267). b. Check internal actuator harness and injector solenoid connector for dirt or moisture in or on connector and for missing or damaged connector seals. Remove dirt and moisture from connector. Replace missing or damaged connector seals (Volume 2, WP 0267). 7. Place ignition switch in OFF position and, with rocker arm cover removed, disconnect actuator harness from 15-pin connector and injector solenoid wires from no. 6 injector solenoid. a. Measure resistance from 15-pin connector pin 1 (or A) to each injector pigtail nut that connects the No. 1 injector (resistance to one of these nuts must be within specifications). Resistance should be less than 10 Ohms. (1) (2) b. If resistance is not as specified, repair or replace connectors (Volume 2, WP 0267). If internal actuator harness requires replacement, notify SRA.

Measure resistance from 15-pin connector pin 2 (or B) to each injector pigtail nut that connects the No. 1 injector (resistance to one of these nuts must be within specifications). Resistance should be less than 10 Ohms.

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0007

ENGINE FUEL INJECTOR CIRCUITS TROUBLESHOOTING - Continued CORRECTIVE ACTION - Continued If resistance is not as specified, notify SRA to replace internal actuator harness.

<10 OHMS

T0061JCH

Figure 28. Injector Wiring Test. 8. Place ignition switch in OFF position and disconnect internal actuator harness from injector solenoid connector and disconnect injector solenoid wires from solenoid. a. Measure resistance from pin A (or 1) of injector solenoid connector to injector wire pigtail nut. Resistance should be less than 10 Ohms. (1) (2) b. If resistance is as specified, notify SRA to replace internal actuator harness. If resistance is not as specified, replace injector solenoid wires (Volume 2, WP 0267).

Measure resistance from pin B (or 2) of injector solenoid connector to injector wire pigtail nut. Resistance should be less than 10 Ohms. (1) (2) If resistance is as specified, notify SRA to replace internal actuator harness. If resistance is not as specified, replace injector solenoid wires (Volume 2, WP 0267).

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0007

ENGINE FUEL INJECTOR CIRCUITS TROUBLESHOOTING - Continued CORRECTIVE ACTION - Continued 9. Place ignition switch in OFF position and, with rocker arm cover removed, disconnect internal actuator harness from 15-pin connector. a. Measure resistance from pin 1 (or A) on internal harness side of actuator harness 15-pin connector to all other pins in connector. Resistance should be greater than 100k Ohms. If resistance is not as specified, notify SRA to replace internal actuator harness. b. Measure resistance from pin 2 (or B) on internal harness side of actuator harness 15-pin connector to all other pins in connector. Resistance should be greater than 100k Ohms. If resistance is not as specified, notify SRA to replace internal actuator harness.

>100K OHMS

>100K OHMS

T0062JCH

Figure 29. Actuator Harness Test. 10. Place ignition switch in OFF position and, with rocker arm cover removed, disconnect injector solenoid connector on internal actuator harness from no. 6 injector solenoid. a. Measure resistance from pin 1 (or A) on solenoid connector to engine block ground. Resistance should be greater than 100k Ohms. If resistance is not as specified, notify SRA to replace internal actuator harness. b. Measure resistance from pin 2 (or B) on solenoid connector to engine block ground. Resistance should be greater than 100k Ohms. If resistance is not as specified, notify SRA to replace internal actuator harness.

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0007

ENGINE FUEL INJECTOR CIRCUITS TROUBLESHOOTING - Continued CORRECTIVE ACTION - Continued

>100K OHMS

T0063JCH

Figure 30. Actuator Harness Test. 11. 12. Place ignition switch in OFF position and, with rocker arm cover removed, disconnect no. 6 injector solenoid from internal actuator harness. Measure resistance from post to post on solenoid. Resistance should be 0.5 to 1.5 Ohms. a. b. SYMPTOM If resistance is as specified, replace engine ECU (WP 0099). If resistance is not as specified, replace injector (WP 0067).

ERROR CODE 1331 MALFUNCTION Injector Circuit Failure. CORRECTIVE ACTION

WARNING

Injector solenoids receive high voltage when engine is operating. To avoid personal injury or death from electrical shock, do not wear jewelry or damp clothing, and do not touch injector solenoids or solenoid wires when engine is operating. 1. Place ignition switch in OFF position and disconnect actuator harness from engine ECU.

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0007

ENGINE FUEL INJECTOR CIRCUITS TROUBLESHOOTING - Continued CORRECTIVE ACTION - Continued a. Inspect actuator harness and ECU connector for dirty, corroded, bent, broken, pushed back, and extended pins. Clean and repair connector(s) as required (Volume 2, WP 0267). b. Check actuator harness and ECU connector for dirt or moisture in or on connector and for missing or damaged connector seals. Remove dirt and moisture from connector. Replace missing or damaged connector seals (Volume 2, WP 0267). 2. Place ignition switch in OFF position and disconnect actuator harness from engine ECU and 15-pin connector at front of engine below rocker arm cover. Install jumper wire from pin 3 to pin 4 at 15-pin connector, actuator harness side. Measure resistance from actuator harness connector pin 8 to pin 7. Resistance should be less than 10 Ohms. a. b. If resistance is not as specified, repair or replace connectors (Volume 2, WP 0267). If engine harness requires replacement, notify SRA.

3.

<10 OHMS

T0064JCH

Figure 31. Actuator Harness Test. 4. Place ignition switch in OFF position and disconnect actuator harness from engine ECU and 15-pin connector at front of engine below rocker arm cover. Disconnect sensor harness from engine ECU. a. Measure resistance from actuator harness connector pin 7 to all pins in actuator harness connector. Resistance should be greater than 100k Ohms. (1) (2) b. If resistance is not as specified, repair or replace connectors (Volume 2, WP 0267). If engine harness requires replacement, notify SRA.

Measure resistance from actuator harness connector pin 7 to all pins in sensor harness connector. Resistance should be greater than 100k Ohms.

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0007

ENGINE FUEL INJECTOR CIRCUITS TROUBLESHOOTING - Continued CORRECTIVE ACTION - Continued (1) (2) c. If resistance is not as specified, repair or replace connectors (Volume 2, WP 0267). If engine harness requires replacement, notify SRA.

Measure resistance from actuator harness connector pin 8 to all pins in actuator harness connector. Resistance should be greater than 100k Ohms. (1) (2) If resistance is not as specified, repair or replace connectors (Volume 2, WP 0267). If engine harness requires replacement, notify SRA.

d.

Measure resistance from actuator harness connector pin 8 to all pins in sensor harness connector. Resistance should be greater than 100k Ohms. (1) (2) If resistance is not as specified, repair or replace connectors (Volume 2, WP 0267). If engine harness requires replacement, notify SRA.

>100K OHMS

T0065JCH

Figure 32. Actuator Harness Test.

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0007

ENGINE FUEL INJECTOR CIRCUITS TROUBLESHOOTING - Continued CORRECTIVE ACTION - Continued 5. Place ignition switch in OFF position and disconnect actuator harness 15-pin connector at front of engine below rocker arm cover. Disconnect actuator harness connector from engine ECU. a. Measure resistance from actuator harness connector pin 7 to engine block ground. Resistance should be greater than 100k Ohms. (1) (2) b. If resistance is not as specified, repair or replace connectors (Volume 2, WP 0267). If engine harness requires replacement, notify SRA.

Measure resistance from actuator harness connector pin 8 to engine block ground. Resistance should be greater than 100k Ohms. (1) (2) If resistance is not as specified, repair or replace connectors (Volume 2, WP 0267). If engine harness requires replacement, notify SRA.

>100K OHMS

T0066JCH

Figure 33. Actuator Harness Test. 6. Place ignition switch in OFF position. Remove rocker arm cover (WP 0057). Disconnect injector solenoid connector from no. 2 injector solenoid and internal actuator harness from 15-pin connector. a. Inspect internal actuator harness and injector solenoid connector for dirty, corroded, bent, broken, pushed back, and extended pins. Clean and repair connector(s) as required (Volume 2, WP 0267). b. Check internal actuator harness and injector solenoid connector for dirt or moisture in or on connector and for missing or damaged connector seals. Remove dirt and moisture from connector. Replace missing or damaged connector seals (Volume 2, WP 0267). 7. Place ignition switch in OFF position and, with rocker arm cover removed, disconnect actuator harness from 15-pin connector and injector solenoid wires from no. 2 injector solenoid.

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0007

ENGINE FUEL INJECTOR CIRCUITS TROUBLESHOOTING - Continued CORRECTIVE ACTION - Continued a. Measure resistance from 15-pin connector pin 1 (or A) to each injector pigtail nut that connects the no. 1 injector (resistance to one of these nuts must be within specifications). Resistance should be less than 10 Ohms. (1) (2) b. If resistance is not as specified, repair or replace connectors (Volume 2, WP 0267). If internal actuator harness requires replacement, notify SRA.

Measure resistance from 15-pin connector pin 2 (or B) to each injector pigtail nut that connects the no. 1 injector (resistance to one of these nuts must be within specifications). Resistance should be less than 10 Ohms. If resistance is not as specified, notify SRA to replace internal actuator harness.

<10 OHMS

T0067JCH

Figure 34. Actuator Harness Test. 8. Place ignition switch in OFF position and disconnect internal actuator harness from injector solenoid connector and disconnect injector solenoid wires from solenoid. a. Measure resistance from pin A (or 1) of injector solenoid connector to injector wire pigtail nut. Resistance should be less than 10 Ohms. (1) (2) b. If resistance is as specified, notify SRA to replace internal actuator harness. If resistance is not as specified, replace injector solenoid wires.

Measure resistance from pin B (or 2) of injector solenoid connector to injector wire pigtail nut. Resistance should be less than 10 Ohms. (1) (2) If resistance is as specified, notify SRA to replace internal actuator harness. If resistance is not as specified, replace injector solenoid wires.

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0007

ENGINE FUEL INJECTOR CIRCUITS TROUBLESHOOTING - Continued CORRECTIVE ACTION - Continued 9. Place ignition switch in OFF position and, with rocker arm cover removed, disconnect internal actuator harness from 15-pin connector. a. Measure resistance from pin 1 (or A) on internal harness side of actuator harness 15-pin connector to all other pins in connector. Resistance should be greater than 100k Ohms. If resistance is not as specified, notify SRA to replace internal actuator harness. b. Measure resistance from pin 2 (or B) on internal harness side of actuator harness 15-pin connector to all other pins in connector. Resistance should be greater than 100k Ohms. If resistance is not as specified, notify SRA to replace internal actuator harness.

>100K OHMS

>100K OHMS

T0068JCH

Figure 35. Actuator Harness Test. 10. Place ignition switch in OFF position and, with rocker arm cover removed, disconnect injector solenoid connector on internal actuator harness from no. 2 injector solenoid. a. Measure resistance from pin 1 (or A) on solenoid connector to engine block ground. Resistance should be greater than 100k Ohms. If resistance is not as specified, notify SRA to replace internal actuator harness. b. Measure resistance from pin 2 (or B) on solenoid connector to engine block ground. Resistance should be greater than 100k Ohms. If resistance is not as specified, notify SRA to replace internal actuator harness.

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0007

ENGINE FUEL INJECTOR CIRCUITS TROUBLESHOOTING - Continued CORRECTIVE ACTION - Continued

>100K OHMS

T0069JCH

Figure 36. Actuator Harness Test. 11. 12. Place ignition switch in OFF position and, with rocker arm cover removed, disconnect no. 2 injector solenoid from internal actuator harness. Measure resistance from post to post on solenoid. Resistance should be 0.5 to 1.5 Ohms. a. b. SYMPTOM ERROR CODE 1332 MALFUNCTION Injector Circuit Failure. CORRECTIVE ACTION If resistance is as specified, replace engine ECU (WP 0099). If resistance is not as specified, replace injector (WP 0067).

WARNING

Injector solenoids receive high voltage when engine is operating. To avoid personal injury or death from electrical shock, do not wear jewelry or damp clothing, and do not touch injector solenoids or solenoid wires when engine is operating. 1. Place ignition switch in OFF position and disconnect actuator harness from engine ECU. a. Inspect actuator harness and ECU connector for dirty, corroded, bent, broken, pushed back, and extended pins.

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0007

ENGINE FUEL INJECTOR CIRCUITS TROUBLESHOOTING - Continued CORRECTIVE ACTION - Continued Clean and repair connector(s) as required (Volume 2, WP 0267). b. Check actuator harness and ECU connector for dirt or moisture in or on connector and for missing or damaged connector seals. Remove dirt and moisture from connector. Replace missing or damaged connector seals (Volume 2, WP 0267). 2. Place ignition switch in OFF position and disconnect actuator harness from engine ECU and 15-pin connector at front of engine below rocker arm cover. Install jumper wire from pin 7 to pin 8 at 15-pin connector, actuator harness side. Measure resistance from actuator harness connector pin 26 to pin 36. Resistance should be less than 10 Ohms. a. b. If resistance is not as specified, repair or replace connectors (Volume 2, WP 0267). If engine harness requires replacement, notify SRA.

3.

<10 OHMS

T0070JCH

Figure 37. Actuator Harness Test. 4. Place ignition switch in OFF position and disconnect actuator harness from engine ECU and 15-pin connector at front of engine below rocker arm cover. Disconnect sensor harness from engine ECU. a. Measure resistance from actuator harness connector pin 26 to all pins in actuator harness connector. Resistance should be greater than 100k Ohms. (1) (2) b. If resistance is not as specified, repair or replace connectors (Volume 2, WP 0267). If engine harness requires replacement, notify SRA.

Measure resistance from actuator harness connector pin 26 to all pins in sensor harness connector. Resistance should be greater than 100k Ohms. (1) (2) If resistance is not as specified, repair or replace connectors (Volume 2, WP 0267). If engine harness requires replacement, notify SRA.

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0007

ENGINE FUEL INJECTOR CIRCUITS TROUBLESHOOTING - Continued CORRECTIVE ACTION - Continued c. Measure resistance from actuator harness connector pin 36 to all pins in actuator harness connector. Resistance should be greater than 100k Ohms. (1) (2) d. If resistance is not as specified, repair or replace connectors (Volume 2, WP 0267). If engine harness requires replacement, notify SRA.

Measure resistance from actuator harness connector pin 36 to all pins in sensor harness connector. Resistance should be greater than 100k Ohms. (1) (2) If resistance is not as specified, repair or replace connectors (Volume 2, WP 0267). If engine harness requires replacement, notify SRA.

>100K OHMS

T0071JCH

Figure 38. Actuator Harness Test.

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0007

ENGINE FUEL INJECTOR CIRCUITS TROUBLESHOOTING - Continued CORRECTIVE ACTION - Continued 5. Place ignition switch in OFF position and disconnect actuator harness 15-pin connector at front of engine below rocker arm cover. Disconnect actuator harness connector from engine ECU. a. Measure resistance from actuator harness connector pin 26 to engine block ground. Resistance should be greater than 100k Ohms. (1) (2) b. If resistance is not as specified, repair or replace connectors (Volume 2, WP 0267). If engine harness requires replacement, notify SRA.

Measure resistance from actuator harness connector pin 36 to engine block ground. Resistance should be greater than 100k Ohms. (1) (2) If resistance is not as specified, repair or replace connectors (Volume 2, WP 0267). If engine harness requires replacement, notify SRA.

>100K OHMS

T0072JCH

Figure 39. Actuator Harness Test. 6. Place ignition switch in OFF position. Remove rocker arm cover (WP 0057). Disconnect injector solenoid connector from no. 4 injector solenoid and internal actuator harness from 15-pin connector. a. Inspect internal actuator harness and injector solenoid connector for dirty, corroded, bent, broken, pushed back, and extended pins. Clean and repair connector(s) as required (Volume 2, WP 0267). b. Check internal actuator harness and injector solenoid connector for dirt or moisture in or on connector and for missing or damaged connector seals. Remove dirt and moisture from connector. Replace missing or damaged connector seals (Volume 2, WP 0267). 7. Place ignition switch in OFF position and, with rocker arm cover removed, disconnect actuator harness from 15-pin connector and injector solenoid wires from no. 4 injector solenoid.

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0007

ENGINE FUEL INJECTOR CIRCUITS TROUBLESHOOTING - Continued CORRECTIVE ACTION - Continued a. Measure resistance from 15-pin connector pin 1 (or A) to each injector pigtail nut that connects the no. 1 injector (resistance to one of these nuts must be within specifications). Resistance should be less than 10 Ohms. (1) (2) b. If resistance is not as specified, repair or replace connectors (Volume 2, WP 0267). If internal actuator harness requires replacement, notify SRA.

Measure resistance from 15-pin connector pin 2 (or B) to each injector pigtail nut that connects the no. 1 injector (resistance to one of these nuts must be within specifications). Resistance should be less than 10 Ohms. If resistance is not as specified, notify SRA to replace internal actuator harness.

<10 OHMS

T0073JCH

Figure 40. Actuator Harness Test. 8. Place ignition switch in OFF position and disconnect internal actuator harness from injector solenoid connector and disconnect injector solenoid wires from solenoid. a. Measure resistance from pin A (or 1) of injector solenoid connector to injector wire pigtail nut. Resistance should be less than 10 Ohms. (1) (2) b. If resistance is as specified, notify SRA to replace internal actuator harness. If resistance is not as specified, replace injector solenoid wires.

Measure resistance from pin B (or 2) of injector solenoid connector to injector wire pigtail nut. Resistance should be less than 10 Ohms. (1) (2) If resistance is as specified, notify SRA to replace internal actuator harness. If resistance is not as specified, replace injector solenoid wires.

9.

Place ignition switch in OFF position and, with rocker arm cover removed, disconnect internal actuator harness from 15-pin connector.

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0007

ENGINE FUEL INJECTOR CIRCUITS TROUBLESHOOTING - Continued CORRECTIVE ACTION - Continued a. Measure resistance from pin 1 (or A) on internal harness side of actuator harness 15-pin connector to all other pins in connector. Resistance should be greater than 100k Ohms. If resistance is not as specified, notify SRA to replace internal actuator harness. b. Measure resistance from pin 2 (or B) on internal harness side of actuator harness 15-pin connector to all other pins in connector. Resistance should be greater than 100k Ohms. If resistance is not as specified, notify SRA to replace internal actuator harness.

>100K OHMS

>100K OHMS

T0074JCH

Figure 41. Actuator Harness Test. 10. Place ignition switch in OFF position and, with rockerarm cover removed, disconnect injector solenoid connector on internal actuator harness from no. 4 injector solenoid. a. Measure resistance from pin 1 (or A) on solenoid connector to engine block ground. Resistance should be greater than 100k Ohms. If resistance is not as specified, notify SRA to replace internal actuator harness. b. Measure resistance from pin 2 (or B) on solenoid connector to engine block ground. Resistance should be greater than 100k Ohms. If resistance is not as specified, notify SRA to replace internal actuator harness.

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0007

ENGINE FUEL INJECTOR CIRCUITS TROUBLESHOOTING - Continued CORRECTIVE ACTION - Continued

>100K OHMS

T0075JCH

Figure 42. Actuator Harness Test. 11. 12. Place ignition switch in OFF position and, with rocker arm cover removed, disconnect no. 4 injector solenoid from internal actuator harness. Measure resistance from post to post on solenoid. Resistance should be 0.5 to 1.5 Ohms. a. b. SYMPTOM If resistance is as specified, replace engine ECU (WP 0099). If resistance is not as specified, replace injector (WP 0067).

ERROR CODE 1951 MALFUNCTION Injector Circuit Failure. CORRECTIVE ACTION Notify SRA.

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0007

ENGINE FUEL INJECTOR CIRCUITS TROUBLESHOOTING - Continued CORRECTIVE ACTION - Continued

T0076JCH

Figure 43. Cylinder #1 Supply and Return.

T0077JCH

Figure 44. Cylinder #5 Supply and Return.

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0007

ENGINE FUEL INJECTOR CIRCUITS TROUBLESHOOTING - Continued CORRECTIVE ACTION - Continued

T0078JCH

Figure 45. Cylinder #3 Supply and Return.

T0079JCH

Figure 46. Cylinder #6 Supply and Return.

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0007

ENGINE FUEL INJECTOR CIRCUITS TROUBLESHOOTING - Continued CORRECTIVE ACTION - Continued

T0080JCH

Figure 47. Cylinder #2 Supply and Return.

T0081JCH

Figure 48. Cylinder #4 Supply and Return. END OF WORK PACKAGE

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0008

FIELD MAINTENANCE ENGINE TPS AND VALIDATION SWITCH TROUBLESHOOTING

INITIAL SETUP: Tools and Special Tools Lead, Test (Volume 2, WP 0277, Table 1, Item 48) Lead, Test (Volume 2, WP 0277, Table 1, Item 49) Multimeter (Volume 2, WP 0277, Table 1, Item 52) References WP 0005 References (cont.) WP 0078 WP 0100 Volume 2, WP 0185 Volume 2, WP 0267 Volume 2, WP 0272 Volume 2, WP 0277

NOTE
Refer to Troubleshooting Symptom Index (WP 0005) for additional troubleshooting guidance, information, and illustrations that locate critical components.

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0008

TROUBLESHOOTING PROCEDURE ENGINE TPS AND VALIDATION SWITCH TROUBLESHOOTING SYMPTOM

ERROR CODE 1131 MALFUNCTION High Voltage Detected at Throttle Position Sensor Circuit. CORRECTIVE ACTION

NOTE
Use test lead, female - part number 3823994 (Volume 2, WP 0277, Table 1, Item 47) to test connector X690. Use test lead, male - part number 3822758 (Volume 2, WP 0277, Table 1, Item 49) to test the OEM harness connector. 1. Inspect the accelerator pedal assembly for damage and wiring harness connection (WP 0078). Replace damaged accelerator pedal or connect disconnected wiring harness (WP 0078). Check connector. Access the cab distribution box in the panel behind the operators seat. Pull the box out and disconnect connector X23. Inspect connector X23 for damage. Check resistance on the loose part of connector X23 between pins 4 and 5. Resistance should be 2,000 to 3,000 Ohms (Figure 3 (Volume 2, WP 0272)). a. b. 4. If resistance is not as specified, continue with Step 4. Repair or replace damaged connector (Volume 2, WP 0267).

2. 3.

Check resistance on the loose part of connector X23 between pins 3 and 4. Resistance should be 1,500 to 3,000 Ohms with the pedal released and 250 to 1,500 Ohms with the pedal depressed (Figure 3 (Volume 2, WP 0272)). If resistance is not as specified, continue with Step 5. Check connector. Remove the kick panel from in front of the steering column to access the X690 connector on the accelerator pedal wiring harness. Check for continuity. Disconnect X690 and inspect for damage. Check resistance on the accelerator pedal part of connector X690 between pins 4 and 5. Check each pin for continuity to ground. Resistance should be 2,000 to 3,000 Ohms and there should be no continuity to ground (Figure 3 (Volume 2, WP 0272)).

5. 6.

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0008

ENGINE TPS AND VALIDATION SWITCH TROUBLESHOOTING - Continued CORRECTIVE ACTION - Continued

2000-3000 OHMS

PIN 5 X690 BK 6 RD 5 WH 4 PIN 4 USE TEST LEAD KIT P/N 3823994


T0082JCH

1 OR 2 GN 3 BU

Figure 1. Accelerator Pedal Wiring Test.

0008-3

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0008

ENGINE TPS AND VALIDATION SWITCH TROUBLESHOOTING - Continued CORRECTIVE ACTION - Continued 7. Check resistance on the accelerator pedal part of connector X690 between pins 5 and 6. Check each pin for continuity to ground. Resistance should be 1,500 to 3,000 Ohms with the pedal released and 250 to 1,500 Ohms With the pedal depressed. There should be continuity to ground (Figure 3 (Volume 2, WP 0272)). a. b. c. d. If resistance is not as specified, replace accelerator pedal assembly (WP 0078). If resistance is as specified, check continuity and for continuity to ground for wires 233, 234, and 235 (Figure 3 (Volume 2, WP 0272)). Repair or replace damaged connector (Volume 2, WP 0267). Replace damaged, open, shorted, or grounded X690 to X23 wiring harness (Volume 2, WP 0267).
1500-3000 OHMS RELEASED 250-1500 OHMS DEPRESSED

PIN 6 BK 6 RD 5 WH 4 USE TEST LEAD KIT P/N 3823994 PIN 5

X690 1 OR 2 GN 3 BU
T0083JCH

Figure 2. Accelerator Pedal Wiring Test. 8. Inspect pins. Reconnect connector X23 and connector X690. Remove the engine cover (Volume 2, WP 0185). Disconnect the OEM harness connector from ECU (794) (WP 0100). Inspect the OEM harness connector and ECU pins for damage, dirt, or corrosion. a. b. Clean and repair connector as required (Volume 2, WP 0267). Replace damaged ECU (794) (WP 0100).

0008-4

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0008

ENGINE TPS AND VALIDATION SWITCH TROUBLESHOOTING - Continued CORRECTIVE ACTION - Continued

1500-3000 Ohms

USE TEST LEAD KIT P/N 3822758

T0084JCH

Figure 3. OEM Harness Connector Test. 9. Check resistance at the OEM harness connector between pins 48 and 49. Resistance should be 2,000 to 3,000 Ohms (Figure 3 (Volume 2, WP 0272)). If resistance is not as specified, proceed with Step 10. Check resistance at the OEM harness connector between pins 47 and 48. Resistance should be 1,500 to 3,000 Ohms with the pedal released and 250 to 1,500 Ohms with the pedal depressed (Figure 3 (Volume 2, WP 0272)). If resistance is not as specified, proceed with Step 11.

10.

>1500-3000 OHMS RELEASED 250-1500 Ohms DEPRESSED

USE TEST LEAD KIT P/N 3822758

T0085JCH

Figure 4. OEM Harness Connector Test.

0008-5

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0008

ENGINE TPS AND VALIDATION SWITCH TROUBLESHOOTING - Continued CORRECTIVE ACTION - Continued 11. Check for continuity. Disconnect connector X16 and the OEM harness connector. Check continuity and for continuity to ground for wires 163, 164, and 165 (Figure 3 (Volume 2, WP 0272)). If continuity to ground is found at any one wire or any wire is found to be open, notify SRA. Check for continuity. Disconnect connector X16 and inspect for damage. Check continuity and for continuity to ground for wires A163, A164, and A165 (Figure 3 (Volume 2, WP 0272)). a. b. 13. Repair or replace damaged connector (Volume 2, WP 0267). Replace any damaged, open, or grounded wires.

12.

Check for continuity. Disconnect the OEM harness connector and connector X16. Check for continuity on the OEM harness connector between pin 47 and all of the other pins in the connector. There should be continuity between pins. If there is continuity between pin 47 and any other pin in the OEM harness connector, notify SRA.

>1500-3000 OHMS RELEASED 250-1500 Ohms DEPRESSED

USE TEST LEAD KIT P/N 3822758

T0085JCH

Figure 5. OEM Harness Connector Test.

0008-6

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0008

ENGINE TPS AND VALIDATION SWITCH TROUBLESHOOTING - Continued

SYMPTOM

ERROR CODE 1132 MALFUNCTION Low Voltage Detected at Throttle Position Sensor Circuit. CORRECTIVE ACTION

NOTE
Use test lead, female - part number 3823994 (Volume 2, WP 0277, Table 1, Item 47) to test connector X690. Use test lead, male - part number 3822758 (Volume 2, WP 0277, Table 1, Item 49) to test the OEM harness connector. 1. Inspect the accelerator pedal assembly for damage and wiring harness connection (WP 0078). Replace damaged accelerator pedal or connect disconnected wiring harness (WP 0078). Check connector. Access the cab distribution box in the panel behind the operators seat. Pull the box out and disconnect connector X23. Inspect connector X23 for damage. Check resistance on the loose part of connector X23 between pins 4 and 5. Resistance should be 2,000 to 3,000 Ohms (Figure 3 (Volume 2, WP 0272)). a. b. 4. If resistance is not as specified, continue with Step 4. Repair or replace damaged connector (Volume 2, WP 0267).

2. 3.

Check continuity on the loose part of connector X23 between pin 3 and ground and pin 4 and ground. There should be continuity to ground (Figure 3 (Volume 2, WP 0272)). If continuity to ground is found continue with Step 5. Inspect wiring. Remove the kick panel from in front of the steering column to access the X690 connector on the accelerator pedal wiring harness.

5.

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0008

ENGINE TPS AND VALIDATION SWITCH TROUBLESHOOTING - Continued CORRECTIVE ACTION - Continued 6. Check for continuity. Disconnect connector X690 and inspect for damage. Check resistance on the acceleration pedal part of connector X690 between pins 4 and 5. Check each pin for continuity to ground. Resistance should be 2,000 to 3,000 Ohms and there should not be continuity to ground (Figure 3 (Volume 2, WP 0272)). a. b. If resistance is not as specified; replace accelerator pedal assembly (WP 0078). Repair or replace damaged connector (Volume 2, WP 0267).

2000-3000 OHMS

PIN 4 BK 6 RD 5 WH 4 USE TEST LEAD KIT P/N 3823996 PIN 5

X690 1 OR 2 GN 3 BU
T0087JCH

Figure 6. Accelerator Pedal Wiring Test. 7. Check continuity on the accelerator pedal part of connector X690 between pin 5 and ground and pin 6 and ground. There should be continuity to ground (Figure 3 (Volume 2, WP 0272)). a. b. c. d. If continuity to ground is found, replace accelerator pedal assembly (WP 0078). If continuity to ground is not found, check continuity and for continuity to ground for wires 233, 234, and 235 (Figure 3 (Volume 2, WP 0272)). Repair or replace damaged connector (Volume 2, WP 0267). Replace damaged, open, shorted, or grounded X690 to X23 wiring harness (Volume 2, WP 0267).

0008-8

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0008

ENGINE TPS AND VALIDATION SWITCH TROUBLESHOOTING - Continued CORRECTIVE ACTION - Continued

X690 BK 6 RD 5 WH 4 1 OR 2 GN 3 BU
T0088JCH

PIN 5 AND PIN 6 USE TEST LEAD KIT P/N 3823996

Figure 7. Accelerator Pedal Wiring Test. 8. Inspect pins. Remove the engine cover (Volume 2, WP 0185). Disconnect the OEM harness connector from ECU (794) (WP 0100). Inspect the OEM harness connector and ECU pins for damage, dirt, or corrosion. a. b. 9. Clean and repair connector as required (Volume 2, WP 0267). Replace damaged ECU (794) (WP 0100).

Check for continuity. Disconnect connector X16 and the OEM harness connector. Check continuity and for continuity to ground for wires 163, 164, and 165 (Figure 3 (Volume 2, WP 0272)). If continuity to ground is found at any one wire or any wire is found to be open, notify SRA. Check for continuity. Disconnect connector X16 and inspect for damage. Check continuity and for continuity to ground for wires A163, A164, and A165 (Figure 3 (Volume 2, WP 0272)). a. b. Repair or replace damaged connector (Volume 2, WP 0267). Replace any damaged, open or grounded wires.

10.

0008-9

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0008

ENGINE TPS AND VALIDATION SWITCH TROUBLESHOOTING - Continued CORRECTIVE ACTION - Continued

T0089JCH

Figure 8. OEM Wiring Harness Test. 11. Check for continuity. Disconnect the OEM harness connector and connector Xl6. Check for continuity on the OEM harness connector between pin 47 and all of the other pins in the connector and between pin 48 and all of the other pins in the connector. There should be continuity between pins. If there is continuity between pin 47 or 48 and any other pin in the OEM harness connector, notify SRA.

T0090JCH

Figure 9. OEM Wiring Harness Test.

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0008

ENGINE TPS AND VALIDATION SWITCH TROUBLESHOOTING - Continued SYMPTOM

ERROR CODE 1431 MALFUNCTION Voltage Detected at Both Idle Validation Signal Circuits. CORRECTIVE ACTION

NOTE
Use test lead, female - part number Volume 2, WP 0277, Table 1, Item 47 to test connector X690. Use test lead, male - part number 3822758 (Volume 2, WP 0277, Table 1, Item 49) to test the OEM harness connector. 1. Check calibration. Turn the ignition on and depress and release the accelerator pedal three times to calibrate the pedal. If ERROR CODE remains active continue with Step 2.
3 TIMES

T0091JCH

Figure 10. Accelerator Pedal Calibration. 2. Inspect the accelerator pedal assembly for damage and wiring harness connection (WP 0078). Replace damaged accelerator pedal or connect disconnected wiring harness (WP 0078). Inspect connector X23 for damage. Access the cab distribution box in the panel behind the operators seat. Pull the box out and disconnect connector X23. Repair or replace damaged connector (Volume 2, WP 0267). Check resistance on the loose part of connector X23 between pins 6 and 9. Resistance should be <125 Ohms with the pedal released. Check resistance between 7 and 9. Resistance should be <125 Ohms with the pedal depressed (Figure 3 (Volume 2, WP 0272)). If resistance is not as specified continue with Step 5.

3.

4.

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0008

ENGINE TPS AND VALIDATION SWITCH TROUBLESHOOTING - Continued CORRECTIVE ACTION - Continued 5. Check continuity on the loose part of connector X23 between pins 6 and 7 while depressing and releasing the pedal. There should be continuity (Figure 3 (Volume 2, WP 0272)). If resistance is not as specified, continue with Step 6. Check for resistance. Remove the kick panel from in front of the steering column to access the X690 connector on the accelerator pedal wiring harness. a. b. 7. If resistance is not as specified, replace accelerator pedal assembly (WP 0078). Repair or replace damaged connector (Volume 2, WP 0267).

6.

Check for resistance. Disconnect connector X690 and inspect for damage. Check resistance on the accelerator pedal part of connector X690 between pins 1 and 3. Resistance should be <125 Ohms with the pedal released. Check resistance between pins 1 and 2. Resistance should be <125 Ohms with the pedal depressed (Figure 3 (Volume 2, WP 0272)). a. b. c. d. If resistance is not as specified, replace accelerator pedal assembly (WP 0078). If resistance is as specified, check continuity and for continuity between wires for wires 233, 234, and 235. Repair or replace damaged connector (Volume 2, WP 0267). Replace damaged, open, shorted, or grounded X690 to X23 wiring harness (Volume 2, WP 0267).
<125 OHMS <125 OHMS

1,3 X690 BK 6 RD 5 WH 4 1 OR 2 GN 3 BU

1,2

USE TEST LEAD KIT P/N 3822917

T0092JCH

Figure 11. Accelerator Pedal Test. 8. Check resistance on the accelerator pedal part of connector X690 between pins 2 and 3 while depressing and releasing the pedal. There should be continuity (Figure 3 (Volume 2, WP 0272)). a. b. If voltage (4.75V to 5.25V) is not as specified, continue with Step 9. Repair or replace damaged connector (Volume 2, WP 0267).

0008-12

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0008

ENGINE TPS AND VALIDATION SWITCH TROUBLESHOOTING - Continued CORRECTIVE ACTION - Continued

>100K OHMS

X690 BK 6 RD 5 WH 4 USE TEST LEAD KIT P/N 3822917 1 OR 2 GN 3 BU

2,3

T0093JCH

Figure 12. Accelerator Pedal Resistance Test. 9. Inspect connector X16 for damage. Reconnect connector X23 and disconnect connector X16. Turn the ignition on and check for voltage at connector X16 between pin 3 and ground and pin 13 and ground (Figure 3 (Volume 2, WP 0272)). There should be 4.75V to 5.25V at each pin. a. b. Clean and repair connector as required (Volume 2, WP 0267). Replace damaged ECU (794) (WP 0100).

4.75-5.25V

USE TEST LEAD KIT P/N 3822917

T0094JCH

Figure 13. Idle Validation Circuit Voltage Test.

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0008

ENGINE TPS AND VALIDATION SWITCH TROUBLESHOOTING - Continued CORRECTIVE ACTION - Continued 10. Inspect the OEM harness connector and ECU pins for damage, dirt or corrosion. Remove engine cover (Volume 2, WP 0185). Disconnect the OEM harness connector from ECU (794) (WP 0100). Check for continuity. Disconnect connector X16 and the OEM harness connector. Check continuity of wires 166, 167, and 168 (Figure 3 (Volume 2, WP 0272)). a. b. c. 12. If continuity at any one wire is not found, replace engine and transmission wiring harness Electrical General Maintenance Instructions (Volume 2, WP 0267)). Perform voltage check in Step 9 again. Replace ECU (794) (WP 0100) if Step 9 voltage check fails.

11.

Check for continuity. Disconnect connector X16 and inspect for damage. Check continuity and for continuity to ground for wires A166, A167, and A168 (Figure 3 (Volume 2, WP 0272)). a. b. Repair or replace damaged connector (Volume 2, WP 0267). Replace any damaged, open, or grounded wires.

13.

Check for continuity. Disconnect the OEM harness connector and connector X16. Check for continuity on the OEM harness connector between pin 3 and all of the other pins in the connector. Check continuity between pin 13 and all of the other pins in the connector. There should not be continuity between pins. If there is continuity between pin 3 or pin 13 and any other pin in the OEM harness connector, notify SRA.
>100K OHMS >100K OHMS

T0095JCH

Figure 14. Idle Validation Circuit Voltage Test.

0008-14

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0008

ENGINE TPS AND VALIDATION SWITCH TROUBLESHOOTING - Continued

SYMPTOM

ERROR CODE 1432 MALFUNCTION Wrong Voltage Signals Detected at Throttle Position Sensor and Idle Validation Circuits. CORRECTIVE ACTION

NOTE
Use test lead, female - part number 3823994 (Volume 2, WP 0277, Table 1, Item 47) to test connector X690. Use test lead, male - part number 3822758 (Volume 2, WP 0277, Table 1, Item 49) to test the OEM harness connector. 1. Check calibration. Turn the ignition on and depress and release the accelerator pedal three times to calibrate the pedal. If ERROR CODE remains active, continue with the troubleshooting procedure. 2. Inspect the accelerator pedal assembly for damage and wiring harness connection (WP 0078). Replace damaged accelerator pedal or connect disconnected wiring harness (WP 0078). Check connector. Access the cab distribution box in the panel behind the operators seat. Pull the box out and disconnect connector X23. Check resistance on the loose part of connector X23 between pins 3 and 4. Resistance should be 1,500 to 3,000 Ohms with the pedal released and 250 to 1,500 Ohms with the pedal depressed (Figure 3 (Volume 2, WP 0272)). The difference in the two resistance values must be at least 1,000 Ohms. a. b. 5. If resistance is not as specified, continue with Step 5. Repair or replace damaged connector (Volume 2, WP 0267).

3. 4.

Check connector. Remove the kick panel from in front of the steering column to access the X690 connector on the accelerator pedal wiring harness. Check connector X690 for damage. Repair or replace damaged connector (Volume 2, WP 0267).

0008-15

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0008

ENGINE TPS AND VALIDATION SWITCH TROUBLESHOOTING - Continued CORRECTIVE ACTION - Continued 6. Check resistance on the accelerator pedal part of connector X690 between pins 5 and 6. Resistance should be 1,500 to 3,000 Ohms with the pedal released and 250 to 1,500 Ohms with the pedal depressed (Figure 3 (Volume 2, WP 0272)). The difference in the two resistance values must be least 1,000 Ohms. a. b. If resistance is not as specified, replace accelerator pedal assembly (WP 0078). Repair or replace damaged connector (Volume 2, WP 0267).

USE TEST LEAD KIT P/N 3822917 1500-3000 OHMS RELEASED 250-1500 OHMS DEPRESSED

X690 BK 6 RD 5 WH 4 1 OR 2 GN 3 BU

5,6

NOTE: RELEASED VALUE MUST BE AT LEAST 1000 OHMS GREATER THAN DEPRESSED VALUE

T0096JCH

Figure 15. TPS and Idle Validation Circuit Voltage Test. 7. Check continuity of wires 233, 234, and 235 between connector X690 and connector X23 (Figure 3 (Volume 2, WP 0272)). a. b. 8. Repair or replace damaged connector (Volume 2, WP 0267). Replace damaged, open, shorted, or grounded X690 to X23 wiring harness (Volume 2, WP 0267).

Inspect the OEM harness connector and ECU pins for damage, dirt or corrosion. Remove the engine cover (Volume 2, WP 0185). Disconnect the OEM harness connector from ECU (794) (WP 0100). a. b. Clean and repair connector as required (Volume 2, WP 0267). Replace damaged ECU (794) (WP 0100).

9.

Disconnect connector X16 and the OEM harness connector. Check continuity of wires 163, 164, and 165 (Figure 3 (Volume 2, WP 0272)). If continuity of any wire is not found, replace engine and transmission wiring harness (Volume 2, WP 0267).

0008-16

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0008

ENGINE TPS AND VALIDATION SWITCH TROUBLESHOOTING - Continued CORRECTIVE ACTION - Continued 10. Check connector and wires. Disconnect connector X16 and inspect for damage. Check continuity of wires A163, A164, and A165 (Figure 3 (Volume 2, WP 0272)). a. b. 11. Repair or replace damaged connector (Volume 2, WP 0267). Replace any damaged, open, or grounded wires.

Check for continuity. Disconnect the OEM harness connector and connector Xl6. Check for continuity on the OEM harness connector between pin 47 and all of the other pins in the connector, between pin 48 and all the other pins in the connector and between pin 49 and all of the other pins in the connector. There should not be continuity between pins. If there is continuity between pin 47, 48, or 49 and any other pin in the OEM harness connector, replace the engine and transmission wiring harness (Volume 2, WP 0267).

>100K OHMS

T0097JCH

Figure 16. TPS and Idle Validation Circuit Voltage Test.

0008-17

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0008

ENGINE TPS AND VALIDATION SWITCH TROUBLESHOOTING - Continued

SYMPTOM

ERROR CODE 1551 MALFUNCTION No Voltage Detected at Both Idle Validation Signal Circuits. CORRECTIVE ACTION

NOTE
Use test lead, female - part number 3823994 (Volume 2, WP 0277, Table 1, Item 47) to test connector X690. Use test lead, male - part number 3822758 (Volume 2, WP 0277, Table 1, Item 49) to test the OEM harness connector. Perform the troubleshooting procedure for ERROR CODE 1431. END OF WORK PACKAGE

0008-18

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0009

FIELD MAINTENANCE COOLING FAN OPERATION AND FAN CONTROL TROUBLESHOOTING

INITIAL SETUP: Tools and Special Tools Multimeter (Volume 2, WP 0277, Table 1, Item 52) References TM 10-3930-675-10 WP 0005 References (cont.) WP 0100 WP 0116 Volume 2, WP 0228 Volume 2, WP 0267 Volume 2, WP 0272

NOTE
Refer to Troubleshooting Symptom Index (WP 0005) for additional troubleshooting guidance, information, and illustrations that locate critical components. Refer also to illustration at end of work package for component location.

0009-1

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0009

TROUBLESHOOTING PROCEDURE COOLING FAN OPERATION AND FAN CONTROL TROUBLESHOOTING SYMPTOM

TEST OR INSPECTION11(13) DIAG SERVO OUTPUT/INPUT FAN 0mA 0mA BL.VALVE 0.00V 0mA

ERROR CODE 166 MALFUNCTION Cooling Fan Speed, Wiring Circuit Failure. CORRECTIVE ACTION 1. Enter DIAG SERVO 11(13)" in the diagnostic menu and observe the FAN" OUTPUT" and INPUT" should have mA values. a. b. 2. If no OUTPUT" mA values display, enter into diagnostic menus to check vehicle temperature sensors for proper operation. If no INPUT" mA values display, continue with Step 2.

Enter DIAG EXTRA FUNCT 11(13)". Check voltage at X158 between pin 10 and ground while changing the fan speed using the +/- menu selection buttons (Figure 2 (Volume 2, WP 0272)). The voltage should vary with fan speed; 10 to 22V. a. b. c. d. If no voltage (10 to 22V) is found, disconnect X158 and check the resistance on the loose part of X158 between 9 and pin 10. Resistance should be 8 to 10 Ohms. If voltage (10 to 22V) is found, disconnect ECU (790) connector 2 and check pin 13 for damage and check continuity of wire A15810 (Figure 2 (Volume 2, WP 0272)). Repair or replace damaged wires or connectors (Volume 2, WP 0267). Replace damaged ECU (790) (WP 0100).

3.

Remove the rear radiator top grating to access to the cooling fan flow control valve. Unplug the harness and check the resistance of the valve solenoid (6037). Should be 8 to 10 Ohms. a. b. c. If resistance (8 to 10 Ohms) is not as specified, replace the cooling fan flow control valve (Volume 2, WP 0228). If specified resistance is found, check continuity of wires 1589 and 15810 (Figure 2 (Volume 2, WP 0272)). Replace damaged open or shorted harness (Volume 2, WP 0267).

0009-2

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0009

COOLING FAN OPERATION AND FAN CONTROL TROUBLESHOOTING - Continued SYMPTOM

DIAG SERVO 11(13) OUTPUT/INPUT 0mA 0mA FAN BL.VALVE 0.00V 0mA

ERROR CODE 167 MALFUNCTION Cooling Fan Speed, Short Circuit Failure. CORRECTIVE ACTION 1. Enter DIAG SERVO 11(13)" in the diagnostic menu and observe the FAN OUTPUT" and INPUT" should have mA values. a. b. 2. If no OUTPUT" mA values display, enter into diagnostic menus to check vehicle temperature sensors for proper operation. If no INPUT" mA values display, continue with Step 2.

Enter DIAG EXTRA FUNCT 11(13)". Check voltage at X158 between pin 10 and ground while changing the fan speed using the +/- menu selection buttons (Figure 2 (Volume 2, WP 0272)). The voltage should vary with fan speed; 10 to 22V. a. If no voltage (10 to 22V) is found, disconnect X158 and check the resistance on the loose part of X158 between pin 9 and pin 10. Resistance should be 8 to 10 Ohms. Check continuity of each pin to ground. If voltage (10-22V) is found, disconnect ECU (790) connector 2 and check pin 13 for damage and check continuity of wire A15810 and continuity of wire to ground (Figure 2 (Volume 2, WP 0272)). Repair or replace damaged, shorted wires or connectors (Volume 2, WP 0267). Replace damaged ECU (790) (WP 0100).

b.

c. d. 3.

Remove the rear radiator top grating to access to the cooling fan flow control valve. Unplug the harness and check the resistance of the valve solenoid (6037). Should be 8 to 10 Ohms. Check solenoid for short to ground. a. b. c. If resistance (8 to 10 Ohms) is not as specified or shorted to ground, replace the cooling fan flow control valve (Volume 2, WP 0228). If specified resistance is found, check continuity of wires 1589 and 15810 (Figure 2 (Volume 2, WP 0272)). Replace damaged open or shorted harness (Volume 2, WP 0267).

0009-3

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0009

COOLING FAN OPERATION AND FAN CONTROL TROUBLESHOOTING - Continued

SYMPTOM

ERROR CODE 426 MALFUNCTION Fording Level Switch, Circuit Input Error. CORRECTIVE ACTION

NOTE
ERROR CODE 426 is an information type ERROR CODE. It may not activate for the operator. Enter DIAG STEERING 2(16)" in the diagnostic menu to verify the code or enable the information type codes in the Initialization menu. Input error type codes can be activate if the voltage input is not stable due to a bad connection. 1. 2. Inspect the fording level switch for damage and connection. Replace damaged fording level switch (WP 0116). Inspection connectors X195 and X198 (located under the cab and rear cover plate) for connection or damage. a. b. c. 3. Repair or replace damaged connector (Volume 2, WP 0267). If connectors are found to be in good condition, check wires BK, GY, and WH (Figure 7 (Volume 2, WP 0272)) for continuity. Replace or repair open or damaged wire or replace X198 to X195 cable, electrical general maintenance (Volume 2, WP 0267).

Check ECU (792) pin 103 for connection or damage (Figure 5 (Volume 2, WP 0272)). a. b. Check wire A19512 for continuity (Figure 5 (Volume 2, WP 0272)). Replace damaged ECU (792) terminal board (WP 0100).

4.

Check for wire connection. Disconnect wire A19512 from ECU (792) and recheck for active 426 ERROR CODE. a. b. Replace ECU (792) (WP 0100) if ERROR CODE 426 is still ACTIVE. Replace fording level switch (WP 0116).

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0009

COOLING FAN OPERATION AND FAN CONTROL TROUBLESHOOTING - Continued CORRECTIVE ACTION - Continued

T0100JCH

Figure 1. Cooling Fan Diagnostics. END OF WORK PACKAGE

0009-5/6 blank

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0010

FIELD MAINTENANCE OVERLOAD PROTECTION TROUBLESHOOTING

INITIAL SETUP: Tools and Special Tools Lead, Test (Volume 2, WP 0277, Table 1, Item 48) Lead, Test (Volume 2, WP 0277, Table 1, Item 49) Multimeter (Volume 2, WP 0277, Table 1, Item 52) References TM 10-3930-675-10 WP 0005 References (cont.) WP 0006 WP 0100 WP 0121 WP 0122 WP 0124 Volume 2, WP 0245 Volume 2, WP 0257 Volume 2, WP 0258 Volume 2, WP 0267 Volume 2, WP 0272

NOTE
Refer to Troubleshooting Symptom Index (WP 0005) to for additional troubleshooting guidance, information, and illustrations that locate critical components. Refer also to illustrations at end of work package for component location. TROUBLESHOOTING PROCEDURE OVERLOAD PROTECTION TROUBLESHOOTING SYMPTOM

ERROR CODE 130 MALFUNCTION Overload Protection System. CORRECTIVE ACTION Overload protection system is not working due to an earlier failure 131 to 136 (ERROR CODES 131 to 136) on any component related to the overload protection system. Hydraulic speeds are limited and the ERROR CODE will flash on the display every 5 seconds. Troubleshoot original ERROR CODES 131 to 136.

0010-1

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0010

OVERLOAD PROTECTION TROUBLESHOOTING - Continued SYMPTOM

ERROR CODE 131 MALFUNCTION

DIAG SERVO SYSTEM POWER POWER RI CAN POWER LE CAN 10V REF OUT

1(13) 24.00V 24.00V 24.00V 10.00V

Boom Extension Sensor or Circuit Failure. CORRECTIVE ACTION 1. Look inside the small inspection hole at the rear of the boom and check if the extension steel cable is attached and the harness is connected. a. b. c. 2. Remove rear boom cover and reattach steel cable to boom extension, inspect sensor and harness for damage (WP 0122). Reconnect disconnected harness (WP 0122). Replace damaged boom extension sensor (WP 0122).

Check boom wear plates and for sticking boom extension or retraction while operating. (A sticking boom, especially in the fully lowered position, will activate ERROR CODE 131.) a. b. Clean boom wear plate surfaces and replace any worn or damaged wear plates (Volume 2, WP 0258). Check boom system hydraulic pressures (Volume 2, WP 0245) and perform hydraulic system troubleshooting (WP 0006).

3.

Enter DIAG SERVO 7(13)" in the diagnostic menu and check length sensor voltage. The voltage should be around <1 to 4V retracted to extended. a. b. If no voltage (<1 to 4V) is found, check voltage (10V) at X157 between pins 2 and 3 (Figure 2 (Volume 2, WP 0272)). If no voltage (10V) is found at X157 between pins 2 and 3, check continuity of wires A15514A, A15514B, A15514C, A15513D, A15513B, A15513A, and A1571 (Figure 2 (Volume 2, WP 0272)). Repair or replace damaged wires or connectors (Volume 2, WP 0267).

c. 4.

Inspect ECU (790) connector 1 pins 13, 26, and 27 and connector for damage. a. b. Repair or replace damaged wires or connectors (Volume 2, WP 0267). Replace damaged ECU (790) (WP 0100).

5.

Check voltage (10V) at X169 between pins 2 and 3 and voltage (<1 to 4V) between pins 1 and 3 with the ignition ON (Figure 2 (Volume 2, WP 0272)).

0010-2

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0010

OVERLOAD PROTECTION TROUBLESHOOTING - Continued CORRECTIVE ACTION - Continued a. b. c. 6. If no voltage (10V) is found at X169 between pins 2 and 3, check continuity of wires BK, RD and GY (Figure 2 (Volume 2, WP 0272)). If no voltage is (<1 to 4V) found, (Step 6), replace boom extension sensor (WP 0122). Replace damaged or open harness (Volume 2, WP 0267).

Remove the rear boom cover to gain access to the boom extension sensor (WP 0122). Inspect sensor and harness for damage. a. b. c. Disconnect the sensor harness and inspect pins and check continuity of harness wires. Inspect the steel cable by pulling it slowly from the sensor and retracting. Replace damaged or faulty boom extension sensor (WP 0122).

SYMPTOM

DIAG SERVO SYSTEM POWER POWER RI CAN POWER LE CAN 10V REF OUT

1(13) 24.00V 24.00V 24.00V 10.00V

ERROR CODE 132 MALFUNCTION Boom Angle Sensor or Circuit Failure. CORRECTIVE ACTION 1. Look under the rear of the boom and check the boom angle sensor for damage and proper mounting. Replace damaged boom angle sensor (WP 0121). Enter DIAG SERVO 7(13)" in the diagnostic menu and check angle sensor voltage. The voltage should be around 8V with the boom fully lowered. a. b. If no voltage (8V) is found, check voltage (10V) at X157 between pins 2 and 3 (Figure 2 (Volume 2, WP 0272)). If no voltage (10V) is found at X157 between pins 2 and 3, check continuity of wires A15514A, A15514B, A15514C, A15513D, A15513C, A15513B, A15513A, and A1571 (Figure 2 (Volume 2, WP 0272)). Repair or replace damaged wires or connectors (Volume 2, WP 0267).

2.

c.

0010-3

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0010

OVERLOAD PROTECTION TROUBLESHOOTING - Continued CORRECTIVE ACTION - Continued 3. Inspect ECU (790) connector 1 pins 16, 26, and 27 and connector for damage. a. b. 4. Repair or replace damaged wires or connectors (Volume 2, WP 0267). Replace damaged ECU (790) (WP 0100).

Check voltage (10V) at X169 between pins 2 and 3 and voltage (8V) (boom fully lowered between pins 3 and 4 with the ignition ON (Figure 2 (Volume 2, WP 0272)). a. b. c. If no voltage (10V) is found at X169 between pins 2 and 3, check continuity of wires BK, RD and BU (Figure 2 (Volume 2, WP 0272)). If no voltage (8V) is found, replace boom angle sensor (WP 0121). Replace damaged or open harness (Volume 2, WP 0267).

SYMPTOM

DIAG SERVO SYSTEM POWER POWER RI CAN POWER LE CAN 10V REF OUT

1(13) 24.00V 24.00V 24.00V 10.00V

ERROR CODE 133 MALFUNCTION Left Lift Cylinder Pressure Sensor or Circuit Failure. CORRECTIVE ACTION 1. Inspect the left lift cylinder locking valve and pressure sensors for damage and connections. a. b. 2. Reconnect disconnected sensor harness. Replace damaged pressure sensor or harness (WP 0124).

Enter DIAG SERVO 8(13)" in the diagnostic menu and check the pressure sensor voltage. Lift the boom slightly to pressurize the lift cylinders. The voltage should be 3 to 6V depending on boom position. a. Check PRESS LE PRESS" and RETURN" voltages. If the PRESS" voltage (3 to 6V) is not found and RETURN" voltage is <2V, switch the pressure sensor harness leads (768-2 and 768-4) (Figure 2 (Volume 2, WP 0272)). Recheck pressure voltages. If the RETURN" voltage (<2) appears at PRESS", replace 768-2 pressure sensor (WP 0124). Make sure to switch the sensor leads back after the test.

b. 3.

Check voltage (24V) at X159 between pins 3 and 4 with the ignition ON (Figure 2 (Volume 2, WP 0272)).

0010-4

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TM 10-3930-675-23-1

0010

OVERLOAD PROTECTION TROUBLESHOOTING - Continued CORRECTIVE ACTION - Continued a. b. 4. If no voltage (24V) is found, check continuity of wires A1543D, A1543C, A15513C, A15513B, A15513A, and 1543B (Figure 2 (Volume 2, WP 0272)). Repair or replace damaged wires or connectors (Volume 2, WP 0267).

Make sure the boom is slightly raised. Check voltage (3 to 6V) at X159 between pins 6 and 4 with the ignition ON (Figure 2 (Volume 2, WP 0272)). a. b. If voltage (3 to 6V) is found, continue with Step 5. If voltage (3 to 6V) is found, disconnect ECU (790) connector 1 and check pin 17 and connector for damage and check continuity of wire A1596 (Figure 2 (Volume 2, WP 0272)). Repair or replace damaged wires or connectors (Volume 2, WP 0267). Replace damaged ECU (790) (Volume 2, WP 0267).

c. d. 5.

Disconnect sensor harness 768-2 and check voltage (24V) between 1 and 3 with the ignition ON (Figure 2 (Volume 2, WP 0272)). a. b. c. If no voltage (24V) is found, continue with Step 6. If voltage (24V) is found, check sensor pins and harness for damage, seal and tight fit. Replace damaged sensor and harness (WP 0124).

6.

Remove the engine cover to gain access to X167. Check voltage (24V) at X167 between pins 16 and 17 and check voltage (3 to 6V) between pins 17 and 19 with the ignition ON (Figure 2 (Volume 2, WP 0272)). a. b. c. d. e. If no voltage (24V) is found at X167 between pins 16 and 17, check continuity of wires RD, BU, and GN (Figure 2 (Volume 2, WP 0272)). If no voltage (3 to 6V) is found at X167 between pins 17 and 19, check continuity of 768-2 sensor harness (Figure 2 (Volume 2, WP 0272)). Replace damaged sensor and harness (WP 0124). Repair or replace damaged wires or connectors (Volume 2, WP 0267). Replace damaged or open harness (Volume 2, WP 0267).

0010-5

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TM 10-3930-675-23-1

0010

OVERLOAD PROTECTION TROUBLESHOOTING - Continued

SYMPTOM

DIAG SERVO SYSTEM POWER POWER RI CAN POWER LE CAN 10V REF OUT

1(13) 24.00V 24.00V 24.00V 10.00V

ERROR CODE 134 MALFUNCTION Right Lift Cylinder Pressure Sensor or Circuit Failure. CORRECTIVE ACTION 1. Inspect the right lift cylinder locking valve and pressure sensors for damage and connections. a. b. 2. Reconnect disconnected sensor harness. Replace damaged pressure sensor or harness (WP 0124).

Enter DIAG SERVO 8(13)" in the diagnostic menu and check the pressure sensor voltage. Lift the boom slightly to pressurize the lift cylinders. The voltage should be 3 to 6V depending on boom position. a. Check PRESS RI PRESS" and RETURN" voltages. If the PRESS" voltage (3-6V) is not found and RETURN" voltage is <2V, switch the pressure sensor harness leads (768-1 and 768-3) (Figure 2 (Volume 2, WP 0272)). Recheck pressure voltages. If the RETURN" voltage (<2) appears at PRESS", replace 768-1 pressure sensor (WP 0124). Make sure to switch the sensor leads back after the test.

b. 3.

Check voltage (24V) at X159 between pins 3 and 4 with the ignition ON (Figure 2 (Volume 2, WP 0272)). a. b. If no voltage (24V) is found, check continuity of wires A1543D, A1543C, A15513C, A15513B, A15513A, and 1543B (Figure 2 (Volume 2, WP 0272)). Repair or replace damaged wires or connectors (Volume 2, WP 0267).

4.

Make sure the boom is slightly raised. Check voltage (3 to 6V) at X159 between pins 5 and 4 with the ignition ON (Figure 2 (Volume 2, WP 0272)). a. b. If no voltage (3 to 6V) is found, continue with Step 5. If voltage (3 to 6V) is found, disconnect ECU (790) connector 1 and check pin 18 and connector for damage and check continuity of wire A1595 (Figure 2 (Volume 2, WP 0272)). Repair or replace damaged wires or connectors (Volume 2, WP 0267).

c.

0010-6

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TM 10-3930-675-23-1

0010

OVERLOAD PROTECTION TROUBLESHOOTING - Continued CORRECTIVE ACTION - Continued d. 5. Replace damaged ECU (790) (WP 0100).

Disconnect sensor harness 768-1 and check voltage (24V) between 1 and 3 with the ignition ON (Figure 2 (Volume 2, WP 0272)). a. b. c. If no voltage (24V) is found, continue with Step 6. If voltage (24V) is found, check sensor pins and harness for damage, seal, and tight fit. Replace damaged sensor and harness (WP 0124).

6.

Remove the engine cover to gain access to X167. Check voltage (24V) at X167 between pins 16 and 17 and check voltage (3 to 6V) between pins 17 and 18 with the ignition ON (Figure 2 (Volume 2, WP 0272)). a. b. c. d. e. If no voltage (24V) is found at X167 between pins 16 and 17, check continuity of wires RD, BU, and YE (Figure 2 (Volume 2, WP 0272)). If no voltage (3 to 6V) is found at X167 between pins 17 and 18, check continuity of 768-1 sensor harness (Figure 2 (Volume 2, WP 0272)). Replace damaged sensor and harness (WP 0124). Repair or replace damaged wires or connectors (Volume 2, WP 0267). Replace damaged or open harness (Volume 2, WP 0267).

SYMPTOM

DIAG SERVO SYSTEM POWER POWER RI CAN POWER LE CAN 10V REF OUT

1(13) 24.00V 24.00V 24.00V 10.00V

ERROR CODE 135 MALFUNCTION Left Lift Cylinder Piston Pressure Sensor or Circuit Failure. CORRECTIVE ACTION 1. Inspect the left lift cylinder locking valve and pressure sensors for damage and connections. a. b. Reconnect disconnected sensor harness. Replace damaged pressure sensor or harness (WP 0124).

0010-7

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TM 10-3930-675-23-1

0010

OVERLOAD PROTECTION TROUBLESHOOTING - Continued CORRECTIVE ACTION - Continued 2. Enter DIAG SERVO 8(13)" in the diagnostic menu and check the pressure sensor voltage. Lift the boom slightly to pressurize the lift cylinders. The voltage should be normally <2V at all boom positions. a. Check PRESS RI PRESS" and RETURN" voltages. If the RETURN" voltage (<2V) is not found and PRESS" voltage is 3 to 6V, switch the pressure sensor harness leads (768-2 and 768-4) (Figure 2 (Volume 2, WP 0272)). Recheck pressure voltages. IF the PRESS" voltage (3 to 6V) appears at RETURN", replace 768-4 pressure sensor (WP 0124). Make sure to switch the sensor leads back after the test.

b. 3.

Check voltage (24V) at X159 between pins 3 and 4 with the ignition ON (Figure 2 (Volume 2, WP 0272)). a. b. If no voltage (24V) is found, check continuity of wires A1543D, A1543C, A15513C, A15513B, A15513A, and 1543B (Figure 2 (Volume 2, WP 0272)). Repair or replace damaged wires or connectors (Volume 2, WP 0267).

4.

Make sure the boom is slightly raised. Check voltage (<2V) at X159 between pins 7 and 4 with the ignition ON (Figure 2 (Volume 2, WP 0272)). a. b. c. d. If no voltage (<2V) is found, continue with Step 5. If voltage (<2V) is found, disconnect ECU (790) connector 1 and check pin 19 and connector for damage and check continuity of wire A1597 (Figure 2 (Volume 2, WP 0272)). Repair or replace damaged wires or connectors (Volume 2, WP 0267). Replace damaged ECU (790) (WP 0100).

5.

Disconnect sensor harness 768-4 and check voltage (24V) between 1 and 3 with the ignition ON (Figure 2 (Volume 2, WP 0272)). a. b. c. If no voltage (24V) is found, continue with step 6. If voltage (24V) is found, check sensor pins and harness for damage, seal, and tight fit. Replace damaged sensor and harness (WP 0124).

6.

Remove the engine cover to gain access to X167. Check voltage (24V) at X167 between pins 16 and 17 and check voltage (<2V) between pins 17 and 21 with the ignition ON (Figure 2 (Volume 2, WP 0272)). a. b. c. d. e. If no voltage (24V) is found at X167 between pins 16 and 17, check continuity of wires RD, BU, and BN (Figure 2 (Volume 2, WP 0272)). If no voltage (2V) is found at X167 between pins 17 and 21, check continuity of 768-4 sensor harness (Figure 2 (Volume 2, WP 0272)). Replace damaged sensor and harness (WP 0124). Repair or replace damaged wires or connectors (Volume 2, WP 0267). Replace damaged or open harness (Volume 2, WP 0267).

0010-8

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0010

OVERLOAD PROTECTION TROUBLESHOOTING - Continued SYMPTOM

DIAG SERVO SYSTEM POWER POWER RI CAN POWER LE CAN 10V REF OUT

1(13) 24.00V 24.00V 24.00V 10.00V

ERROR CODE 136 MALFUNCTION Right Lift Cylinder Piston Pressure Sensor or Circuit Failure. CORRECTIVE ACTION 1. Inspect the right lift cylinder locking valve and pressure sensors for damage and connections. a. b. 2. Reconnect disconnected sensor harness. Replace damaged pressure sensor or harness (WP 0124).

Enter DIAG SERVO 8(13)" in the diagnostic menu and check the pressure sensor voltage. Lift the boom slightly to pressurize the lift cylinders. The voltage should normally be <2V at all boom positions. a. Check PRESS RI PRESS" and RETURN" voltages. If the RETURN" voltage (<2V) is not found and PRESS" voltage is 3 to 6V, switch the pressure sensor harness leads (768-1 and 768-3) (Figure 2 (Volume 2, WP 0272)). Recheck pressure voltages. If the PRESS" voltage (3 to 6V) appears at RETURN", replace 768-3 pressure sensor (WP 0124). Make sure to switch the sensor leads back after the test.

b. 3.

Check voltage (24V) at X159 between pins 3 and 4 with the ignition. a. b. If no voltage (24V) is found, check continuity of wires A1543D, A1543C, A15513C, A15513B, A15513A, and 1543B (Figure 2 (Volume 2, WP 0272)). Repair or replace damaged wires or connectors (WP 0124).

4.

Make sure the boom is slightly raised. Check voltage (<2V) at X159 between pins 8 and 4 with the ignition ON (Figure 2 (Volume 2, WP 0272)). a. b. c. d. If no voltage (<2V) is found, continue with Step 5. If voltage (<2V) is found, disconnect ECU (790) connector 1 and check pin 20 and connector for damage and check continuity of wire A1598 (Figure 2 (Volume 2, WP 0272)). Repair or replace damaged wires or connectors (Volume 2, WP 0267). Replace damaged ECU (790) (WP 0100).

0010-9

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0010

OVERLOAD PROTECTION TROUBLESHOOTING - Continued CORRECTIVE ACTION - Continued 5. Disconnect sensor harness 768-3 and check voltage (24V) between 1 and 3 with the ignition ON (Figure 2 (Volume 2, WP 0272)). a. b. c. 6. If no voltage (24V) is found, continue with Step 6. If voltage (24V) is found, check sensor pins and harness for damage, seal, and tight fit. Replace damaged sensor and harness (WP 0124).

Remove the engine cover to gain access to X167. Check voltage (24V) at X167 between pins 16 and 17 and check voltage (<2V) between pins 17 and 20 with the ignition ON (Figure 2 (Volume 2, WP 0272)). a. b. c. d. e. If no voltage (24V) is found at X167 between pins 16 and 17, check continuity of wires RD, BU, and WH (Figure 2 (Volume 2, WP 0272)). If no voltage (24V) is found at X167 between pins 17 and 20, check continuity of 768-3 sensor harness (Figure 2 (Volume 2, WP 0272)). Replace damaged sensor and harness (WP 0124). Repair or replace damaged wires or connectors (Volume 2, WP 0267). Replace damaged or open harness (Volume 2, WP 0267).

SYMPTOM

DIAG ATTACH 1(16) SYSTEM POWER 24.00V POWER RI CAN 24.00V POWER LE CAN 24.00V 10 V REF OUT 10.00V

ERROR CODE 210 MALFUNCTION Tophandler Angle Sensor or Circuit Failure. CORRECTIVE ACTION 1. Inspect tophandler angle sensor and lever and bracket for damage and secure mounting. Tighten loose mounting bracket, replace damaged angle sensor or mounting bracket (WP 0122). Enter DIAG ATTACHMENT 2(16)" in the diagnostic menu. Check tilt angle voltage. With boom fully lowered and tophandler level, voltage should be 4 to 6V. Check lever clocking" on angle sensor (Volume 2, WP 0257). Remove the cover from the tophandler junction box to gain access. Check tilt angle sensor cable connections at X180 pins 10, 11, and 12 (Figure 6 (Volume 2, WP 0272)).

2.

3.

0010-10

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TM 10-3930-675-23-1

0010

OVERLOAD PROTECTION TROUBLESHOOTING - Continued CORRECTIVE ACTION - Continued Repair damaged wires or connectors (Volume 2, WP 0267). 4. Check voltage (10V) at X180 between pins 10 and 12 (Figure 6 (Volume 2, WP 0272)) with the ignition ON. a. b. c. 5. If no voltage (10V) is found, check continuity of wires A18010, A1801, and A1802 (Figure 6 (Volume 2, WP 0272)). Repair or replace damaged wires or connectors (Volume 2, WP 0267). Replace ECU (791) (WP 0100).

Check voltage at X180 between pins 10 and 11 (Figure 6 (Volume 2, WP 0272)) with the ignition ON. Voltage should be 0.3 to 9.5V, depending on tophandler tilt. a. b. c. If voltage is not as specified, replace tilt angle sensor (WP 0122). If voltage is as specified, disconnect ECU (791) connector 1 and inspect ECU and connector pins 9, 26, and 27 for damage. Replace ECU (791) (WP 0100).

0010-11

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TM 10-3930-675-23-1

0010

OVERLOAD PROTECTION TROUBLESHOOTING - Continued CORRECTIVE ACTION - Continued

T0108JCH

Figure 1. Overload Protection Diagnostics.

0010-12

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TM 10-3930-675-23-1

0010

OVERLOAD PROTECTION TROUBLESHOOTING - Continued CORRECTIVE ACTION - Continued

T0109JCH

Figure 2. Overload Protection Diagnostics. END OF WORK PACKAGE

0010-13/14 blank

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0011

FIELD MAINTENANCE TOPHANDLER ELECTRONIC CONTROL UNIT (ECU) (791) TROUBLESHOOTING

INITIAL SETUP: References TM 10-3930-675-10 WP 0005 References (cont.) WP 0100 Volume 2, WP 0267

NOTE
Refer to Troubleshooting Symptom Index (WP 0005) troubleshooting guidance, information, and illustrations that locate critical components. Refer also to illustration at end of work package for component location. TROUBLESHOOTING PROCEDURE TOPHANDLER ELECTRONIC CONTROL UNIT (ECU) (791) TROUBLESHOOTING SYMPTOM

ERROR CODE 205 MALFUNCTION Memory Failure. CORRECTIVE ACTION Place ignition switch in OFF position for 30 seconds and then back in ON position. Replace ECU 791 if ERROR CODE is still present (WP 0100). SYMPTOM

ERROR CODE 220 MALFUNCTION Internal Communication Failure, Connector 2. CORRECTIVE ACTION Place ignition switch in OFF position for 30 seconds and then back in ON position. Replace ECU 791 if ERROR CODE is still present (WP 0100).

0011-1

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TM 10-3930-675-23-1

0011

TOPHANDLER ELECTRONIC CONTROL UNIT (ECU) (791) TROUBLESHOOTING - Continued SYMPTOM ERROR CODE 221 MALFUNCTION Internal Communication Failure, Connector 2. CORRECTIVE ACTION Place ignition switch in OFF position for 30 seconds and then back in ON position. Replace ECU 791 if ERROR CODE is still present (Volume 2, WP 0267). SYMPTOM

ERROR CODE 250 MALFUNCTION Internal Communication Failure, Connector 3. CORRECTIVE ACTION Place ignition switch in OFF position for 30 seconds and then back in ON position. Replace ECU 791 if ERROR CODE is still present (Volume 2, WP 0267). SYMPTOM

ERROR CODE 251 MALFUNCTION Internal Communication Failure, Connector 2. CORRECTIVE ACTION Place ignition switch in OFF position for 30 seconds and then back in ON position. Replace ECU 791 if ERROR CODE is still present (Volume 2, WP 0267).

0011-2

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TM 10-3930-675-23-1

0011

TOPHANDLER ELECTRONIC CONTROL UNIT (ECU) (791) TROUBLESHOOTING - Continued CORRECTIVE ACTION - Continued

T0110JCH

Figure 1. Tophandler ECU Diagnostics. END OF WORK PACKAGE

0011-3/4 blank

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0012

FIELD MAINTENANCE ELECTRONIC CONTROL UNIT (ECU) INPUT VOLTAGE TROUBLESHOOTING

INITIAL SETUP: Tools and Special Tools Multimeter (Volume 2, WP 0277, Table 1, Item 52) References WP 0005 WP 0097 WP 0098 WP 0100 WP 0101 WP 0102 References (cont.) WP 0103 WP 0107 WP 0121 WP 0122 WP 0123 WP 0129 WP 0130 Volume 2, WP 0267 Volume 2, WP 0272

NOTE
Refer to Troubleshooting Symptom Index (WP 0005) for additional troubleshooting guidance, information, and illustrations that locate critical components. Refer also to illustration at end of work package for component location. TROUBLESHOOTING PROCEDURE ELECTRONIC CONTROL UNIT (ECU) INPUT VOLTAGE TROUBLESHOOTING SYMPTOM

ERROR CODE 121 MALFUNCTION Supply Voltage to Servo ECU 1 (790) Failure. CORRECTIVE ACTION 1. Check for emergency stop in engaged position. (Multiple ERROR CODES will display if the emergency stop button is engaged during crank and start.) Disengage emergency stop button. (ERROR CODES 121 and 201 will normally be one of the ERROR CODES displayed.) Check voltage (24V) at X154 pins 4 and 1 with the ignition ON (Figure 2 (Volume 2, WP 0272)). a. If no voltage (24V) is found at X154 pin 4, gain access to emergency stop switch and check connections and continuity (WP 0101) and check continuity of wires 1541 and 1544 (Figure 2 (Volume 2, WP 0272)). If no voltage (24V) is found at X154 pin 1, check circuit breaker F30 and continuity of wires A1501 and 301 (Figure 2 (Volume 2, WP 0272)).

2.

b.

0012-1

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TM 10-3930-675-23-1

0012

ELECTRONIC CONTROL UNIT (ECU) INPUT VOLTAGE TROUBLESHOOTING - Continued CORRECTIVE ACTION - Continued c. d. e. 3. Replace damaged or faulty circuit breaker (WP 0103). Repair or replace damaged wires or connectors (Volume 2, WP 0243). Replace damaged or faulty emergency stop switch (WP 0101).

Disconnect ECU (790) connector 1 and check voltage (24V) at pins 1 and 15 with the ignition ON (Figure 2 (Volume 2, WP 0272)). Inspect ECU (790) connector 1 pins and connector for damage. a. b. c. If no voltage (24V) is found, check continuity of wires A1544A and A1544B (Figure 2 (Volume 2, WP 0272)). Repair or replace damaged wires or connectors (Volume 2, WP 0267). Replace damaged ECU (790) (WP 0100).

SYMPTOM

DIAG SERVO SYSTEM POWER POWER RI CAN POWER LE CAN 10V REF OUT

1(13) 24.00V 24.00V 24.00V 10.00V

ERROR CODE 122 MALFUNCTION Supply Voltage to Servo ECU (790) Failure. CORRECTIVE ACTION 1. 2. Check circuit breaker F32 for trip. Reset circuit breaker as required. Check voltage (24V) at X150 pin 2 with the ignition ON (Figure 2 (Volume 2, WP 0272)). a. b. c. 3. If no voltage (24V) is found, check circuit breaker F32 and continuity of wire 302 (Figure 2 (Volume 2, WP 0272)). Replace damaged or faulty circuit breaker (WP 0103). Repair or replace damaged wires or connectors (Volume 2, WP 0267).

Disconnect ECU (790) connector 1 and check voltage (24V) at pins 7 and 8 with the ignition ON (Figure 2 (Volume 2, WP 0272)). Inspect ECU (790) connector 1 pins and connector for damage. a. b. c. If no voltage (24V) is found, check continuity of wires A1502A and A1502B (Figure 2 (Volume 2, WP 0272)). Repair or replace damaged wires or connectors (Volume 2, WP 0267). Replace damaged ECU (790) (WP 0100).

0012-2

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TM 10-3930-675-23-1

0012

ELECTRONIC CONTROL UNIT (ECU) INPUT VOLTAGE TROUBLESHOOTING - Continued SYMPTOM

DIAG SERVO SYSTEM POWER POWER RI CAN POWER LE CAN 10V REF OUT

1(13) 24.00V 24.00V 24.00V 10.00V

ERROR CODE 123 MALFUNCTION 10V Reference Voltage for Servo ECU (790) Short Circuit Failure. CORRECTIVE ACTION 1. lnspect ECU (790) connector 1. Check connector, harness, and ECU (790) for damage. a. b. 2. Repair or replace damaged wires or connectors (Volume 2, WP 0267). Replace damaged ECU (790) (WP 0100).

Enter DIAG SERVO 1(13)" in the diagnostic menu. The 10V REF OUT" voltage should be around 10V. If voltage is <1V, unplug X155 and X157 and recheck 10V REF OUT" voltage. If voltage (10V) returns, continue with Step 3. Reconnect X155 and but leave X157 unplugged. Enter DIAG SERVO 1(13)" in the diagnostic menu. Check 10V REF OUT" voltage. a. b. If voltage is <1V, unplug the joystick (WP 0102) and recheck 10V REF OUT" voltage. If voltage (10V) returns, replace joystick (WP 0101). If voltage is 10V, continue with Step 4.

3.

4.

Reconnect X157 and enter DIAG SERVO 1(13)" in the diagnostic menu. Check 10V REF OUT" voltage. a. b. c. If voltage is <1V, disconnect the BK wire from X169 pin 2 (Figure 2 (Volume 2, WP 0272)) and recheck 10V REF OUT" voltage. If voltage (10V) returns, continue with Step 5. If voltage (10V) does not return, check wire BK for short to ground (Volume 2, WP 0267). Replace shorted harness (Volume 2, WP 0267).

5.

Reconnect X169 pin 2 wire BK. Disconnect wire GY from X169 pin 2 (Figure 2 (Volume 2, WP 0272)). Enter DIAG SERVO 1(13)" in the diagnostic menu. Check 10V REF OUT" voltage. If voltage is <1V, disconnect X169 pin 2 wire GN and recheck 10V REF OUT" voltage. If voltage (10V) returns, replace boom angle sensor (WP 0121). Reconnect X169 pin 2 wire GY. Disconnect wire GN from X169 pin 2 (Figure 2 (Volume 2, WP 0272)). Enter DIAG SERVO 1(13)" in the diagnostic menu. Check 10V REF OUT" voltage. If voltage is <1V, disconnect X169 pin 2 wire GY again and recheck 10V REF OUT" voltage. If voltage (10V) returns, replace boom extension sensor (WP 0122).

6.

0012-3

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0012

ELECTRONIC CONTROL UNIT (ECU) INPUT VOLTAGE TROUBLESHOOTING - Continued SYMPTOM

ERROR CODE 201

DIAG ATTACHMENT 1(16) SYSTEM POWER 24.00V POWER RI CAN 24.00V POWER LE CAN 24.00V 10 V REF OUT 10.00V

MALFUNCTION Supply Voltage to Tophandler ECU (791) Failure. CORRECTIVE ACTION 1. Check for emergency stop in engaged position. (Multiple ERROR CODES Will display if the emergency stop button is engaged during crank and start.) Disengage emergency stop button. (ERROR CODES 121 and 201 will normally be one of the ERROR CODES displayed.) Check voltage (24V) at X154 pins 2 and 3 with the ignition ON (Figure 2 (Volume 2, WP 0272)). a. If no voltage (24V) is found at X154 pin 3, gain access to emergency stop switch and check connections and continuity (WP 0102) and check continuity of wires 1542 and 1543A (Figure 2 (Volume 2, WP 0272)). If no voltage (24V) is found at X154 pin 1, check circuit breaker F30 and continuity of wires A1504 and 304 (Figure 2 (Volume 2, WP 0272)). Replace damaged of faulty circuit breaker (WP 0103). Repair or replace damaged wires or connectors (Volume 2, WP 0267). Replace damaged or faulty emergency stop switch (WP 0102)).

2.

b. c. d. e. 3.

Check voltage (24V) at X155 pin 11 (Figure 2 (Volume 2, WP 0272)) and X161 pin 3 (Figure 2 (Volume 2, WP 0272)) with the ignition ON. a. b. c. If no voltage (24V) is found at X155 pin 11, check continuity of wire 1542 and 1543A (Figure 2 (Volume 2, WP 0272)). If no voltage (24V) is found at X161 pin 3, check continuity of wire A1543B (Figure 2 (Volume 2, WP 0272)). Repair or replace damaged wires or connectors (Volume 2, WP 0267).

4.

Remove the cover from the tophandler junction box to gain access. Check voltage (24V) at X180 pin 3 (Figure 6 (Volume 2, WP 0272)) with the ignition ON. a. If no voltage (24V) is found at X180 pin 3, check continuity of wire GY between X180 and X185 (Figure 6 (Volume 2, WP 0272)) and wire GY between X185 and X161 and wire A1543C (Figure 2 (Volume 2, WP 0272)). Repair or replace damaged wires or connectors (Volume 2, WP 0267).

b.

0012-4

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0012

ELECTRONIC CONTROL UNIT (ECU) INPUT VOLTAGE TROUBLESHOOTING - Continued CORRECTIVE ACTION - Continued c. 5. Replace damaged open or shorted harness (Volume 2, WP 0267) and (WP 0107).

Check voltage (24V) between X186 pins 1 and 2 (Figure 6 (Volume 2, WP 0272)). a. b. c. d. e. If no voltage (24V) is found, check circuit breaker F40 located under the auxiliary pump (Figure 8 (Volume 2, WP 0272)). If no voltage (24V) is found, check continuity of wires W28 (Figure 8 (Volume 2, WP 0272)) and wire RD between X187 and X186 pin 1 (Figure 6 (Volume 2, WP 0272)). Replace damaged or faulty circuit breaker (WP 0103). Repair or replace damaged wires or connectors (Volume 2, WP 0267). Replace damaged open or shorted harness (WP 0129), (WP 0130), and (WP 0107).

6.

Remove relay 3009-1 and test (Volume 2, WP 0267). Check voltage (24V) and 3009-1 relay socket pins 30 and 86 with the ignition ON (Figure 6 (Volume 2, WP 0272)). a. b. c. d. e. Replace damaged or faulty 3009-1 relay (WP 0097). If no voltage (24V) is found at 3009-1 pin 30, check circuit breaker F41 (1) and continuity of wires A51B, A51J and A1861A (Figure 6 (Volume 2, WP 0272)). Check operation of relay 315-1 (Figure 6 (Volume 2, WP 0272)). Replace damaged or faulty 315-1 relay (WP 0097). If no voltage (24V) is found at 3009-1 pin 86, check continuity of wire A1803A (Figure 6 (Volume 2, WP 0272)). Repair or replace damaged wires or connectors (Volume 2, WP 0267).

7.

Disconnect ECU (791) connector 1 and check voltage (24V) at pins 1 and 15 with the ignition ON (Figure 6 (Volume 2, WP 0272)). a. If no voltage (24V) is found at ECU (791) connector 1 pins 1 and 15, check operation of relay 3009-2 (Figure 6 (Volume 2, WP 0272)). Replace damaged or faulty 3009-2 relay (WP 0098). If no voltage (24V) is found at ECU (791) connector 1 pins 1 and 15, check continuity of wires A51E, A51F, A51G, and A1803B (Figure 6 (Volume 2, WP 0272)). Repair or replace damaged wires or connectors (Volume 2, WP 0267). Replace ECU (791) (WP 0100).

b. c. d.

0012-5

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TM 10-3930-675-23-1

0012

ELECTRONIC CONTROL UNIT (ECU) INPUT VOLTAGE TROUBLESHOOTING - Continued

SYMPTOM

ERROR CODE 202

DIAG ATTACHMENT 1(16) SYSTEM POWER 24.00V POWER RI CAN 24.00V POWER LE CAN 24.00V 10 V REF OUT 10.00V

MALFUNCTION Supply Voltage to Tophandler ECU (791) Failure. CORRECTIVE ACTION 1. Remove the cover from the tophandler junction box cover to gain access. Check voltage (24V) circuit breaker F41 (1) (Figure 6 (Volume 2, WP 0272)) with the ignition ON. a. b. c. 2. If no voltage (24V) is found at F41 (1), check continuity of wire A511 (Figure 6 (Volume 2, WP 0272)). Replace damaged or faulty circuit breaker (WP 0098). Repair or replace damaged wires or connectors (Volume 2, WP 0267).

Disconnect ECU (791) connector l and check voltage (24V) at pins 7 and 8 with the ignition ON (Figure 6 (Volume 2, WP 0272)). Inspect ECU and connector pins for damage. a. b. c. If no voltage (24V) is found at ECU (791) connector 1 pins 7 and 8, check continuity of wires A51A, A51B, and A51C (Figure 6 (Volume 2, WP 0272)). Repair or replace damaged wires or connectors (Volume 2, WP 0267). Replace ECU (791) (WP 0100).

0012-6

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TM 10-3930-675-23-1

0012

ELECTRONIC CONTROL UNIT (ECU) INPUT VOLTAGE TROUBLESHOOTING - Continued

SYMPTOM

ERROR CODE 203 MALFUNCTION 10V Reference Voltage for Tophandler ECU (791) Failure. CORRECTIVE ACTION 1. Enter DIAG ATTACHMENT 1(16)" in the diagnostic menu. Check 10V REF OUT" value. a. b. 2. Should be around 10V. If no voltage (10V) is found, proceed with Step 2.

Remove the cover from the tophandler junction box to gain access. Check tilt angle sensor and cable for damage (Figure 6 (Volume 2, WP 0272)). Replace damaged tilt angle sensor (WP 0123)). Disconnect the tilt angle sensor from X180 (Figure 6 (Volume 2, WP 0272)) and recheck voltage (10V) in the diagnostic menu. a. b. c. If voltage (10V) returns, replace tilt angle sensor (WP 0123). If voltage (10V) does not return, check continuity to ground for wires A18010, A18011, and A18012 Diagrams (Volume 2, WP 0272). Repair or replace damaged wires or connectors (Volume 2, WP 0267).

3.

4.

Disconnect ECU (791) connector 1 and inspect ECU and connector pins for damage. a. b. Repair or replace damaged wires or connectors (Volume 2, WP 0267). Replace ECU (791) (WP 0100).

0012-7

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TM 10-3930-675-23-1

0012

ELECTRONIC CONTROL UNIT (ECU) INPUT VOLTAGE TROUBLESHOOTING - Continued CORRECTIVE ACTION - Continued

T0115JCH

Figure 1. ECU Input Diagnostics

0012-8

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TM 10-3930-675-23-1

0012

ELECTRONIC CONTROL UNIT (ECU) INPUT VOLTAGE TROUBLESHOOTING - Continued CORRECTIVE ACTION - Continued

T0116JCH

Figure 2. ECU Input Diagnostics

0012-9

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TM 10-3930-675-23-1

0012

ELECTRONIC CONTROL UNIT (ECU) INPUT VOLTAGE TROUBLESHOOTING - Continued CORRECTIVE ACTION - Continued

T0117JCH

Figure 3. ECU Input Diagnostics END OF WORK PACKAGE

0012-10

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TM 10-3930-675-23-1

0013

FIELD MAINTENANCE ECU-TO-ECU COMMUNICATIONS TROUBLESHOOTING

INITIAL SETUP: Tools and Special Tools Lead, Test (Volume 2, WP 0277, Table 1, Item 47) Lead, Test (Volume 2, WP 0277, Table 1, Item 49) Multimeter (Volume 2, WP 0277, Table 1, Item 52) References TM 10-3930-675-10 References (cont.) WP 0005 WP 0096 WP 0100 WP 0103 WP 0107 WP 0129 WP 0130 Volume 2, WP 0267 Volume 2, WP 0272

NOTE
Refer to Troubleshooting Symptom Index (WP 0005) for additional troubleshooting guidance, information, and illustrations that locate critical components. TROUBLESHOOTING PROCEDURE ECU-TO-ECU COMMUNICATIONS TROUBLESHOOTING SYMPTOM

ERROR CODE 103 MALFUNCTION ECU (790) Not Responding (RT 240V1R, RT 240V2 and RT 240V3 only). CORRECTIVE ACTION 1. Check ECU (790) connector 1 for damage or proper connection. a. b. 2. Repair or replace damaged connector (Volume 2, WP 0267). Reconnect disconnected connector.

Check for voltage. Disconnect ECU (790) connector 1 and check voltage (24V) at pins 1, 15, 7, and 8 with the ignition ON (Figure 2 (Volume 2, WP 0272)). a. b. c. If voltage (24V) is not found at any of the pins, use the wiring diagram to check each circuit (Figure 2 (Volume 2, WP 0272)). If voltage (24V) is found on all pins, replace ECU (790) (WP 0096). Repair or replace damaged wires or connectors (Volume 2, WP 0267).

0013-1

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TM 10-3930-675-23-1

0013

ECU-TO-ECU COMMUNICATIONS TROUBLESHOOTING - Continued SYMPTOM

ERROR CODE 105 MALFUNCTION ECU (790) Not Responding. CORRECTIVE ACTION 1. Check ECU (790) connector 1 damage or proper connection. a. b. 2. Repair or replace damaged connector (Volume 2, WP 0267). Reconnect disconnected connector.

Disconnect ECU (790) connector 1 and check voltage (24V) at pins 1, 15, 7, and 8 with the ignition ON (Figure 2 (Volume 2, WP 0272)). a. b. c. If voltage (24V) is not found at any of the pins, use the wiring diagram to check each circuit (Figure 2 (Volume 2, WP 0272)). If voltage (24V) is found on all pins, replace ECU (790) (WP 0096). Repair or replace damaged wires or connectors (Volume 2, WP 0267).

SYMPTOM

ERROR CODE 106 MALFUNCTION ECU (791) Not Responding. CORRECTIVE ACTION 1. Check voltage (24V) at X161 pin 6 with the ignition ON (Figure 1 (Volume 2, WP 0272)). a. b. 2. If no voltage (24V) is found at X161 pin 6, check continuity of wire A1503A (Figure 1 (Volume 2, WP 0272)). Repair or replace damaged wires or connectors (Volume 2, WP 0267).

Remove the cover from the tophandler junction box. Check voltage (24V) between X186 pin 1 and pin 2 and between pin 1 and ground. Check circuit breaker F41 (1) for trip (Figure 6 (Volume 2, WP 0272)). a. If no voltage (24V) is found at X186 pin 1, check circuit breaker F40 located under the auxiliary pump and continuity of cables RD, 1862, W28, and W29 (Figure 6 and Figure 8 (Volume 2, WP 0272)). Repair or replace damaged connectors (Volume 2, WP 0267). Replace damaged cable (WP 0129).

b. c.

0013-2

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0013

ECU-TO-ECU COMMUNICATIONS TROUBLESHOOTING - Continued CORRECTIVE ACTION - Continued d. 3. Reset or replace damaged or faulty circuit breaker (WP 0103).

Check voltage (24V) at X180 pin 6 with the ignition ON (Figure 6 (Volume 2, WP 0272)). a. b. If no voltage (24V) is found at X180 pin 6, check continuity of wire YE between X180 and X185 and YE between X185 and X161 pin 6 (Figure 6 (Volume 2, WP 0272)). Replace damaged cable (WP 0107).

4.

Unplug relay 315-l. Check voltage (24V) between the two pins of the connector with the ignition ON (Figure 6 (Volume 2, WP 0272)). a. If no voltage (24V) is found, check continuity of wire A1806 and the ground connection of wire A1806E at 37 - 55. For RT 240V1R, RT 240V2 and RT 240V3 check continuity of wires A1806, 194H, and A194J (X194 pins H and J) and ground connection of wire A1806E at 37 - 55 (Figure 6 (Volume 2, WP 0272)). If voltage (24V) is found, check relay 315-1 (Volume 2, WP 0267). Repair or replace damaged wires or connectors (Volume 2, WP 0267). Replace damaged or faulty relay (WP 0103).

b. c. d. 5.

Unplug ECU (791) connector 1. Check voltage (24V) at pins 7 and 8 with the ignition ON (Figure 6 (Volume 2, WP 0272)). a. If no voltage (24V) is found at ECU (791) connector 1 pins 7 or 8, check circuit breaker F41 (1) (Volume 2, WP 0267) and continuity of wires A51A, A51B, and A51C (Figure 6 (Volume 2, WP 0272)). Repair or replace damaged wires or connectors (Volume 2, WP 0267). Reset or replace damaged or faulty circuit breaker (WP 0103).

b. c. 6.

Check voltage (24V) at pins 1 and 15 with the ignition ON (Figure 6 (Volume 2, WP 0272)). a. If no voltage (24V) is found at ECU (791) connector 1 pins 1 or 15, check relays 3009-1 and 3009-2 (Volume 2, WP 0267) and continuity of wires A51E, A51F, and A51G (Figure 6 (Volume 2, WP 0272)). Repair or replace damaged wires or connectors (Volume 2, WP 0267). Replace damaged or faulty relay (WP 0103). If voltage (24V) is found at all ECU (791) connector 1 pin checks, replace ECU 791 (WP 0100).

b. c. d.

0013-3

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TM 10-3930-675-23-1

0013

ECU-TO-ECU COMMUNICATIONS TROUBLESHOOTING - Continued

SYMPTOM

ERROR CODE 107 MALFUNCTION Cable Failure Between Tophandler ECU (791) and Display ECU (795). CORRECTIVE ACTION 1. Inspect the CAN-BUS cable and connector (X185) that is mounted on the right side of the boom for damage. Replace damaged cable (WP 0107). Check continuity between X152 pin 1 and X161 pin 4, and X152 pin 2 and X161 pin 5 (Figure 1 (Volume 2, WP 0272)). If continuity is not present, repair or replace damaged wires or connectors (Volume 2, WP 0267). Check continuity between X161 pin 4 and X185 pin 4, and X161 pin 5 and X185 pin 5 (Figure 1 (Volume 2, WP 0272)). If continuity is not present, replace damaged cable (Volume 2, WP 0267). Remove the cover to the tophandler junction box. Check continuity between X185 pin 4 and X180 pin 4, and X185 pin 5 and X180 pin 5 (Figure 1 (Volume 2, WP 0272)). If continuity is not present, replace damaged cable (WP 0107). Check continuity between X180 pin 4 and ECU (791) connector 1 pin 2, and X180 pin 5 and ECU (791) connector 1 pin 3 (Figure 1 (Volume 2, WP 0272)). If continuity is not present, repair or replace damaged wires or connectors (Volume 2, WP 0267). Access display ECU (795) inside drivers control panel (WP 0096). Check continuity between (795) pin 11 and X152 pin 1, and between (795) pin 10 and X152 pm 2 (Figure 1 (Volume 2, WP 0272)). a. b. c. If continuity is not present, repair or replace damaged wires or connectors (Volume 2, WP 0267). If continuity is present, replace ECU (790). Replace ECU (795) (WP 0100).

2.

3.

4.

5.

6.

0013-4

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TM 10-3930-675-23-1

0013

ECU-TO-ECU COMMUNICATIONS TROUBLESHOOTING - Continued

SYMPTOM

ERROR CODE 108 MALFUNCTION Cable Failure Between Tophandler ECU (791) and Servo ECU (790). CORRECTIVE ACTION 1. Inspect the CAN-BUS cable and connector (X185) that is mounted on the right side of the boom for damage. Replace damaged cable (WP 0107). Check continuity between X161 pin 1 and ECU (790) connector 1 pin 2, and X161 pin 2 and ECU (790) connector 1 pin 3 (Figure 1 (Volume 2, WP 0272)). If continuity is not present, repair or replace damaged wires or connectors (Volume 2, WP 0267). Check continuity between X161 pin 1 and X185 pin 1, and X161 pin 2 and X185 pin 2 (Figure 1 (Volume 2, WP 0272)). If continuity is not present, replace damaged cable (Volume 2, WP 0267). Remove the cover to the tophandler junction box. Check continuity between X185 pin 1 and X180 pin 1, and X185 pin 2 and X180 pin 2 (Figure 1 (Volume 2, WP 0272)). If continuity is not present, replace damaged cable (WP 0107). Check continuity between X180 pin 1 and ECU (791) connector 1 pin 4, X180 pin 2 and ECU (791) connector 1 pin 5 (Figure 1 (Volume 2, WP 0272)). a. b. c. If continuity is not present, repair or replace damaged wires or connectors (Volume 2, WP 0267). If continuity is present, replace ECU (791) (WP 0100). Replace ECU (790) (WP 0100).

2.

3.

4.

5.

0013-5

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TM 10-3930-675-23-1

0013

ECU-TO-ECU COMMUNICATIONS TROUBLESHOOTING - Continued

SYMPTOM

ERROR CODE 109 MALFUNCTION Cable Failure Between Servo ECU (790) and Display ECU (795). CORRECTIVE ACTION 1. Check continuity between X152 pin 4 and ECU (790) connector 1 pin 4, and X152 pin 5 and ECU (790) connector 1 pin 5 (Figure 1 (Volume 2, WP 0272)). If continuity is not present, repair or replace damaged wires or connectors (Volume 2, WP 0267). Access display ECU (795) inside drivers control panel (TM 10-3930-675-23). Check continuity between (795) pin 13 and X152 pin 4, and between (795) pin 12 and X152 pin 5 (Figure 1 (Volume 2, WP 0272)). a. b. c. If continuity is not present, repair or replace damaged wires or connectors (Volume 2, WP 0267). If continuity is present, replace ECU (790) (WP 0100). Replace ECU (795) (WP 0100).

2.

0013-6

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TM 10-3930-675-23-1

0013

ECU-TO-ECU COMMUNICATIONS TROUBLESHOOTING - Continued

SYMPTOM

ERROR CODE 110 MALFUNCTION Communication Failure Between Display ECU (795) and Steering ECU (792). CORRECTIVE ACTION 1. 2. 3. 4. Enter EXTRA FUNC 9(13)" in the diagnostic menu. Should have a 1" next to RX 792 STEERING" If there is a 0", continue with Step 2. Check steering ECU (792) terminal board for loose or damaged connections. Replace damaged terminal board or tighten connections. Check ECU (792) pins 159 and 160 for loose connection (Figure 5 (Volume 2, WP 0272)). Tighten loose connections. Inspect jumpers between terminal connections at X179. Check continuity between (792) pin 159 and X179 pin L, and between (792) pin 160 and X179 pin H (Figure 1 (Volume 2, WP 0272)). a. b. 5. If continuity is not present, repair or replace damaged wires or connectors (Volume 2, WP 0267). Replace missing or damaged jumpers.

Check continuity between X179 pin L and X177 pin 8, and between X179 pin H and X177 pin 7 (Figure 1 (Volume 2, WP 0272)). If continuity is not present, repair or replace damaged wires or connectors (Volume 2, WP 0267). Check continuity between X177 pin 8 and X160 pin 8, and between X177 pin 7 and X160 pin 7 (Figure 1 (Volume 2, WP 0272)). If continuity is not present, repair or replace damaged wires or connectors (Volume 2, WP 0267). Check continuity between X160 pin 8 and X152 pin 8, and between X160 pin 7 and X152 pin 7 (Figure 1 (Volume 2, WP 0272)). If continuity is not present, repair or replace damaged wires or connectors (Volume 2, WP 0267). Access display ECU (795) inside drivers control panel (TM 10-3930-675-10). Check continuity between (795) pin 6 and X152 pin 7, and between (795) in 5 and X152 pin 8. a. b. c. If continuity is not present, repair or replace damaged wires or connectors (Volume 2, WP 0267). If continuity is present, replace ECU (792) (WP 0096). Replace ECU (795) (WP 0096).

6.

7.

8.

0013-7

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TM 10-3930-675-23-1

0013

ECU-TO-ECU COMMUNICATIONS TROUBLESHOOTING - Continued

SYMPTOM

ERROR CODE 111 MALFUNCTION Communication Failure Between Display ECU (795) and Transmission ECU (793). CORRECTIVE ACTION 1. 2. 3. 4. Enter EXTRA FUNC 9(13)" in the diagnostic menu. Should have a 1" next to RX 793 GEARBOX". If there is a 0", continue with Step 2. Check transmission ECU (793) for loose or damaged connectors. Replace damaged connector or ECU (793) (WP 0100). Check ECU (793) pins 25 and 26 for loose connectors. Repair any loose or missing connectors (Volume 2, WP 0267). Inspect jumpers between terminal connectors at X179. Check continuity between (793) pin 25 and X179 pin H, and between (793) pin 26 and X179 pin L (Figure 1 (Volume 2, WP 0272)). a. b. 5. If continuity is not present, repair or replace damaged wires or connectors (Volume 2, WP 0267). Replace missing or damaged jumpers.

Check continuity between X179 pin L and X177 pin 8, and between X179 pin H and X177 pin 7 (Figure 1 (Volume 2, WP 0272)). If continuity is not present, repair or replace damaged wires or connectors (Volume 2, WP 0267). Check continuity between X177 pin 8 and X160 pin 8, and between X177 pin 7 and X160 pin 7 (Figure 1 (Volume 2, WP 0272)). If continuity is not present, repair or replace damaged wires or connectors (Volume 2, WP 0267). Check continuity between X160 pin 8 and X152 pin 8, and between X160 pin 7 and X152 pin 7 (Figure 1 (Volume 2, WP 0272)). If continuity is not present, repair or replace damaged wires or connectors (Volume 2, WP 0267). Access display ECU (795) inside drivers control panel (TM 10-3930-675-10). Check continuity between (795) pin 6 and X152 pin 7, and between (795) pin 5 and X152 pin 8 (Figure 1 (Volume 2, WP 0272)). a. b. c. If continuity is not present, repair or replace damaged wires or connectors (Volume 2, WP 0267). If continuity is present, replace ECU (793) (Volume 2, WP 0267). Replace ECU (795) (WP 0100).

6.

7.

8.

0013-8

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TM 10-3930-675-23-1

0013

ECU-TO-ECU COMMUNICATIONS TROUBLESHOOTING - Continued

SYMPTOM

ERROR CODE 112 MALFUNCTION Communication Failure Between Display ECU (795) and Engine ECU (794). CORRECTIVE ACTION 1. Check circuit breaker F13 for trip. a. b. c. d. 2. 3. 4. Reset F13 circuit breaker. Engine will not start if F13 is off. If engine will not start, check voltage at F13, X16 pin 9 and ECU (794) OEM connector pin 38 with the ignition switch ON. If no voltage present, check continuity of wires A169 and 169 (Figure 3 (Volume 2, WP 0272)). Replace damaged or faulty circuit breaker (WP 0103).

Enter EXTRA FUNC 9(13)" in the diagnostic menu. Should have a 1" next to RX 794 ENGINE". If there is a 0", continue with Step 3. Check engine ECU (794) for loose or damaged connectors (Figure 3 (Volume 2, WP 0272)). Replace damaged connector or ECU (794) (WP 0100). Check ECU (794) OEM connector pins 37, 38, and 46 for dirty, corroded, bent, broken, pushed back, or extended pins (Figure 3 (Volume 2, WP 0272)). Clean and repair connector as required (Volume 2, WP 0267). Locate X202 attached the harness just below the ECU (794) OEM connector (Figure 1 (Volume 2, WP 0272)). a. b. c. Check X202 plug connector for damage or loose connection. Unplug X202 and check resistance on the plugged part of the connector between pin 1 and 4. Resistance should be 122 Ohms. Clean and repair connector as required (Volume 2, WP 0267). Replace if damaged.

5.

6.

Inspect jumpers between terminal connectors at X179. Check continuity between (794) OEM pin 37 and X179 pin L, and between (794) OEM pin 46 and X179 pin H (Figure 1 (Volume 2, WP 0272)). a. b. If continuity is not present, repair or replace damaged wires or connectors (Volume 2, WP 0267). Replace missing or damaged jumpers.

7.

Check continuity between X179 pin L and X177 pin 8, and between X179 pin H and X177 pin 7 (Figure 1 (Volume 2, WP 0272)). If continuity is not present, repair or replace damaged wires or connectors (Volume 2, WP 0267).

0013-9

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TM 10-3930-675-23-1

0013

ECU-TO-ECU COMMUNICATIONS TROUBLESHOOTING - Continued CORRECTIVE ACTION - Continued 8. Check continuity between X177 pin 8 and X160 pin 8, and between X177 pin 7 and X160 pin 7 (Figure 1 (Volume 2, WP 0272)). If continuity is not present, repair or replace damaged wires or connectors (Volume 2, WP 0267). Check continuity between X160 pin 8 and X152 pin 8, and between X160 pin 7 and X152 pin 7 (Figure 1 (Volume 2, WP 0272)). If continuity is not present, repair or replace damaged wires or connectors (Volume 2, WP 0267). Access display ECU (795) inside drivers control panel (TM 10-3930-675-10). Check continuity between (795) pin 6 and X152 pin 7, and between (795) pin 5 and X152 pin 8 (Figure 1 (Volume 2, WP 0272)). a. b. c. SYMPTOM If continuity is not present, repair or replace damaged wires or connectors (Volume 2, WP 0267). If continuity is present, replace ECU (794) (WP 0100). Replace ECU (795) (WP 0100).

9.

10.

ERROR CODE 345 MALFUNCTION Communication Failure Between Steering ECU (792) and Display ECU (795). CORRECTIVE ACTION Perform troubleshooting procedure for ERROR CODE 110. SYMPTOM

ERROR CODE 346 MALFUNCTION Communication Failure Between Steering ECU (792) and Transmission ECU (793). CORRECTIVE ACTION 1. 2. Check circuit breakers F27 and F28 for trip. Reset circuit breaker as required. Perform troubleshooting procedure for ERROR CODE 111.

0013-10

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TM 10-3930-675-23-1

0013

ECU-TO-ECU COMMUNICATIONS TROUBLESHOOTING - Continued

SYMPTOM

ERROR CODE 684 MALFUNCTION Communication Failure Between Transmission ECU (793) and Display ECU (795). CORRECTIVE ACTION 1. Perform troubleshooting procedure for ERROR CODE 111.

NOTE
Ensure you disconnect and isolate each connector/circuit mentioned in ERROR CODE 111 steps before checking for continuity to ground. 2. Perform each continuity check for continuity to ground. Replace any wire found to have continuity to ground.

SYMPTOM

ERROR CODE 685 MALFUNCTION ERROR CODE 685 - Communication Failure Between Transmission ECU (793) and Steering ECU (792). CORRECTIVE ACTION 1. Check steering ECU (792) and transmission ECU (793) for loose or damaged connectors. Replace damaged connector (Volume 2, WP 0267) or ECU (792), ECU (793) (WP 0100). Check ECU (792) pins 159 and 160 for loose connection. Tighten loose connections. Inspect jumpers between terminal connections at X179. Check continuity and for continuity to ground between (792) pin 159 and X179 pin L, and between (792) pin 160 and X179 pin H. a. b. c. If continuity is not present, repair any loose or missing connections. Replace missing or damaged jumpers. Replace any grounded wire.

2. 3.

0013-11

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TM 10-3930-675-23-1

0013

ECU-TO-ECU COMMUNICATIONS TROUBLESHOOTING - Continued CORRECTIVE ACTION - Continued 4. Check continuity and for continuity to ground between X179 pin L and (793) pin 26, and between X179 pin H and (793) pin 25. a. b. c. d. SYMPTOM If continuity is not present, repair any loose or missing connections. Replace any grounded wire. Replace ECU (793) (WP 0100). Replace ECU (792) (WP 0100).

ERROR CODE 1285 MALFUNCTION Engine Detects a Communication Failure on the J1939 Datalink. CORRECTIVE ACTION Perform the troubleshooting procedures for ERROR CODE 112. SYMPTOM

ERROR CODE 1286 MALFUNCTION Engine Detects a Communication Failure on the J1939 Datalink. CORRECTIVE ACTION Perform the troubleshooting procedures for ERROR CODE 112. END OF WORK PACKAGE

0013-12

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TM 10-3930-675-23-1

0014

FIELD MAINTENANCE STEERING ECU (792), TRANSMISSION ECU (793), AND ENGINE ECU (794) TROUBLESHOOTING

INITIAL SETUP: Tools and Special Tools Lead, Test (Volume 2, WP 0277, Table 1, Item 49) Multimeter (Volume 2, WP 0277, Table 1, Item 52) References WP 0005 References (cont.) WP 0099 WP 0100 WP 0103 WP 0128 Volume 2, WP 0267 Volume 2, WP 0272

TROUBLESHOOTING PROCEDURE STEERING ECU (792), TRANSMISSION ECU (793), AND ENGINE ECU (794) TROUBLESHOOTING

NOTE
Refer Troubleshooting Symptom Index (WP 0005) for additional troubleshooting guidance, information, and illustrations that locate critical components. Refer also to illustration at end of work package for component location. SYMPTOM

ERROR CODE 300 MALFUNCTION Steering ECU (792) Hardware Failure Troubleshooting Procedures. CORRECTIVE ACTION

NOTE
If the engine is cranked and not started, then recranked without turning the ignition OFF, ERROR CODE 300 may be displayed. Turn off ignition for 30 seconds and restart. 1. 2. Check circuit breakers F26 and F29 for trip. Reset circuit breakers as required (WP 0103). Check Voltage (24V) at X174 pin 3 (Figure 5 (Volume 2, WP 0272)) with the ignition ON. a. b. c. If no Voltage (24V) is found, check circuit breaker F 29 and continuity of wires A473 (Figure 8 (Volume 2, WP 0272)). Replace damaged or faulty circuit breaker (WP 0103). Repair or replace damaged wires or connectors (Volume 2, WP 0267).

0014-1

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TM 10-3930-675-23-1

0014

STEERING ECU (792), TRANSMISSION ECU (793), AND ENGINE ECU (794) TROUBLESHOOTING - Continued CORRECTIVE ACTION - Continued 3. lf circuit breaker F29 trips during operation, check voltage output circuits from ECU (792) for short circuit, brake cooling, auxiliary pump, twistlock, and steering indicator lights. (For RT 240V2 and RT 240V3 Autolube system.) (RT 240V1 only 7208 and 7210 cab proximity switches, filter indicators). Perform appropriate troubleshooting and repairs for short circuit. Check voltage (24V) at X174 pin 14 (Figure 5 (Volume 2, WP 0272)) with the ignition ON. a. b. c. 5. If no voltage (24V) is found, check circuit breaker F26 and continuity of wires A48 (Figure 8 (Volume 2, WP 0272)). Replace damaged or faulty circuit breaker (WP 0103). Repair or replace damaged wires or connectors (Volume 2, WP 0267).

4.

Check voltage (24V) at ECU (792) pin 1 (Figure 5 (Volume 2, WP 0272)) with the ignition ON. a. b. lf no voltage (24V) is found, check continuity of wire A17414 and jumper wire 7923 (Figure 5 (Volume 2, WP 0272)). Repair or replace damaged wires or connectors (Volume 2, WP 0267).

6.

Check voltage (24V) at ECU (792) pin 5 (Figure 5 (Volume 2, WP 0272)) with the ignition ON. a. b. c. If no voltage (24V) is found, check continuity of wire A17414 and jumper wire 7923 (Figure 5 (Volume 2, WP 0272)). Repair or replace damaged wires or connectors (WP 0103). Replace ECU (792) (WP 0100).

SYMPTOM

ERROR CODE 841 MALFUNCTION Transmission ECU (793) Memory Failure. CORRECTIVE ACTION Place ignition switch in OFF position for 30 seconds and then back in ON position. Replace transmission ECU (793) if ERROR CODE is still present (WP 0100).

0014-2

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TM 10-3930-675-23-1

0014

STEERING ECU (792), TRANSMISSION ECU (793), AND ENGINE ECU (794) TROUBLESHOOTING - Continued

SYMPTOM

ERROR CODE 843 MALFUNCTION Application Error Failure. CORRECTIVE ACTION Place ignition switch in OFF position for 30 seconds and then back in ON position. Replace transmission ECU (793) if ERROR CODE still present (WP 0100). SYMPTOM

ERROR CODE 1111 MALFUNCTION Engine ECU (794) Memory Failure. CORRECTIVE ACTION Turn ignition switch to OFF position for 30 seconds and then back to ON position. Replace engine ECU (794) if ERROR CODE still appears (WP 0099). SYMPTOM

ERROR CODE 1341 MALFUNCTION Engine ECU (794) Loss of Data Failure. CORRECTIVE ACTION 1. Ensure ignition switch is in OFF position. Disconnect OEM harness from engine ECU (794) and perform the following resistance checks: If resistance is not as specified, repair engine harness connectors (Volume 2, WP 0267). Notify Sustainment Maintenance to replace engine harness. a. b. Measure resistance from OEM harness connector pin 7 to positive (+) battery terminal. Resistance should be less than 10 Ohms. Measure resistance from OEM harness connector pin 8 to positive (+) battery terminal. Resistance should be less than 10 Ohms.

0014-3

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TM 10-3930-675-23-1

0014

STEERING ECU (792), TRANSMISSION ECU (793), AND ENGINE ECU (794) TROUBLESHOOTING - Continued CORRECTIVE ACTION - Continued c. d. e. Measure resistance from OEM harness connector pin 17 to positive (+) battery terminal. Resistance should be less than 10 Ohms. Measure resistance from OEM harness connector pin 18 to positive (+) battery terminal. Resistance should be less than 10 Ohms. Measure resistance from OEM harness connector pin 28 to positive (+) battery terminal. Resistance should be less than 10 Ohms.

USE TEST LEAD KIT P/N 3822758

<10 OHMS
T0118JCH

Figure 1. Use Test Lead Kit. 2. Turn ignition switch to ON position and check battery voltage by placing positive (+) probe of multimeter on positive (+) battery terminal and touch negative (-) probe to negative (-) battery terminal while trying to start engine. Voltage should be at least (+) 12V during normal conditions and at least (+) 6V during cranking. Check each battery in the same way. If voltage is not as required, charge or replace battery (WP 0128).

0014-4

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0014

STEERING ECU (792), TRANSMISSION ECU (793), AND ENGINE ECU (794) TROUBLESHOOTING - Continued CORRECTIVE ACTION - Continued

T0119JCH

Figure 2. Engine ECU Circuit Test. 3. 4. Turn ignition switch to OFF position and check battery terminals for secure connection. Clean terminals and tighten loose battery terminal connections. Check circuit breakers 51-F4 and 51-F5. a. b. SYMPTOM Reset circuit breakers, if tripped. If circuit breakers will not reset, notify SRA.

ERROR CODE 1343 MALFUNCTION Engine ECU (794) Internal Communication Failure. CORRECTIVE ACTION 1. Ensure ignition switch is in OFF position and check all engine and vehicle power and ground connections for corrosion and loose connections. a. b. 2. Tighten loose connections. Repair or replace damaged connections (Volume 2, WP 0267).

With ignition switch in OFF position, disconnect OEM harness from engine ECU (794). Disconnect positive (+) and negative (-) battery cables from battery.

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0014

STEERING ECU (792), TRANSMISSION ECU (793), AND ENGINE ECU (794) TROUBLESHOOTING - Continued CORRECTIVE ACTION - Continued 3. 4. Check engine ECU (794) connectors for moisture. Dry connectors as required. Check all power resistances: If resistance is not as specified, repair engine harness connectors (Volume 2, WP 0267). Notify SRA to replace engine harness. a. b. c. d. e. Measure resistance from engine harness connector pin 7 to positive (+) battery terminal. Resistance should be less than 10 Ohms. Measure resistance from engine harness connector pin 8 to positive (+) battery terminal. Resistance should be less than 10 Ohms. Measure resistance from engine harness connector pin 17 to positive (+) battery terminal. Resistance should be less than 10 Ohms. Measure resistance from engine harness connector pin 18 to positive (+) battery terminal. Resistance should be less than 10 Ohms. Measure resistance from engine harness connector pin 28 to positive (+) battery terminal. Resistance should be less than 10Ohms.

<10 OHMS
T0120JCH

Figure 3. Engine ECU Circuit Test.

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0014

STEERING ECU (792), TRANSMISSION ECU (793), AND ENGINE ECU (794) TROUBLESHOOTING - Continued CORRECTIVE ACTION - Continued 5. Check all ground resistances: If resistance is not as specified, repair engine harness. Notify SRA to replace engine harness. a. b. c. Measure resistance from engine harness connector pin 29 to negative (-) battery terminal. Resistance should be less than 10 Ohms. Measure resistance from engine harness connector pin 30 to negative (-) battery terminal. Resistance should be less than 10 Ohms. Measure resistance from engine harness connector pin 39 to negative (-) battery terminal. Resistance should be less than 10 Ohms.

<10 OHMS
T0121JCH

Figure 4. Engine ECU Circuit Test. d. e. Measure resistance from engine harness connector pin 40 to negative (-) battery terminal. Resistance should be less than 10 Ohms. Measure resistance from engine harness connector pin 50 to negative (-) battery terminal. Resistance should be less than 10 Ohms.

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STEERING ECU (792), TRANSMISSION ECU (793), AND ENGINE ECU (794) TROUBLESHOOTING - Continued

SYMPTOM

ERROR CODE 1346 MALFUNCTION Engine ECU (794) Software Failure. CORRECTIVE ACTION Turn ignition switch to OFF position for 30 seconds and then back to ON position. Replace engine ECU (794) if ERROR CODE still appears (WP 0099).

T0122JCH

Figure 5. Engine ECU Test. END OF WORK PACKAGE

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0015

FIELD MAINTENANCE ELECTRONIC CONTROL UNIT (ECU) SUPPLY VOLTAGE TROUBLESHOOTING

INITIAL SETUP: Tools and Special Tools Multimeter (Volume 2, WP 0277, Table 1, Item 52) References WP 0005 WP 0091 WP 0092 References (cont.) WP 0100 WP 0103 WP 0125 WP 0128 WP 0129 Volume 2, WP 0267 Volume 2, WP 0272

TROUBLESHOOTING PROCEDURE ELECTRONIC CONTROL UNIT (ECU) SUPPLY VOLTAGE TROUBLESHOOTING

NOTE
Refer to Troubleshooting Symptom Index (WP 0005) for additional troubleshooting guidance, information, and illustrations that locate critical components. SYMPTOM

ERROR CODE 451 MALFUNCTION Voltage Supply Too High for Steering ECU (792). CORRECTIVE ACTION Check output voltage from alternator. If output voltage is greater than 33V, replace alternator (WP 0091).

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0015

ELECTRONIC CONTROL UNIT (ECU) SUPPLY VOLTAGE TROUBLESHOOTING - Continued

SYMPTOM

ERROR CODE 452 MALFUNCTION Voltage Supply Too Low for Steering ECU (792). CORRECTIVE ACTION 1. 2. Ensure circuit breakers F26 and F29 are not tripped. Reset circuit breaker(s). Check voltage (22V to 26V) at connector X174 at pins 3 and 14 with the engine running (Figure 5 (Volume 2, WP 0272)). a. b. c. d. 3. If voltage is found but less than 18V, check the condition and charge of the vehicle batteries. Check voltage output of alternator at either NATO slave receptacle. Charge or replace discharged vehicle batteries (WP 0128) and Battery Cables Replacement (WP 0129). Replace non-operational alternator (WP 0091).

Check for voltage (22V to 26V) at connector X174 at pins 3 and 14 with the engine running (Figure 5 (Volume 2, WP 0272)). a. b. c. d. If no voltage (22V to 26V) is found at either pin, check circuit breakers F26 and F29 and continuity of wires A473, A478 (Figure 5 (Volume 2, WP 0272)). Replace damaged or non-operational circuit breaker (WP 0103). Repair or replace damaged connector (Volume 2, WP 0267). Replace damaged or open wire.

4.

Check for voltage (22V to 26V) at ECU (792) at pins 1, 3, 4, and 5 with the ignition ON (Figure 5 (Volume 2, WP 0272)). a. b. c. d. If voltage (22V to 26V) is found, replace ECU (792) (WP 0100). If no voltage (22V to 26V) is found at any one pin, check continuity of wires Al74l4, 7923 and A1743A 00-16). Repair or replace damaged connector (Volume 2, WP 0267). Replace damaged or open wire.

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ELECTRONIC CONTROL UNIT (ECU) SUPPLY VOLTAGE TROUBLESHOOTING - Continued

SYMPTOM

ERROR CODE 453 MALFUNCTION Wheel Sensor Supply Voltage Out of Range (RT 240V1R, RT 240V2 and RT 240V3). CORRECTIVE ACTION 1. Check for voltage (5V) at connector X171 between pins 4 and 6, and 12 and 14 (Figure 5 (Volume 2, WP 0272)). a. b. c. d. 2. If voltage (5V) is not found, perform the following checks: Disconnect connector X170 and recheck for voltage at X171 between pins 4 and 6, and 12 and 14. If voltage (5V) is still not found, perform Step 2. If voltage (5V) returns after disconnecting X170, perform Step 3.

Check for voltage (5V) at connector X170 at pins 4 and 6, and 12 and 14 (Figure 5 (Volume 2, WP 0272)). a. b. c. If voltage (5V) is not found, perform the following checks: Disconnect connector X171 and recheck for voltage at X170 between pins 4 and 6, and 12 and 14. b. If voltage (5V) is still not found, perform Step 5.

3.

Check for continuity. Disconnect connector X170 and check for continuity to ground at pins 4 and 12 (Figure 5 (Volume 2, WP 0272)). There should not be continuity to ground. a. b. c. If continuity to ground is found at pin 4, disconnect wire BU from connector X192 pin 4 and recheck (Figure 5 (Volume 2, WP 0272)). If continuity to ground is found at pin 12, disconnect wire OR from connector X192 pin 12 and recheck (Figure 5 (Volume 2, WP 0272)). Replace grounded X170 to X192 cable (Volume 2, WP 0267).

4.

Check for continuity. Disconnect all of the numbered wires from connector X192 and check each one for continuity to ground (Figure 5 (Volume 2, WP 0272)). If continuity to ground is found at any numbered wire, determine which wheel sensor it belongs to. Replace grounded wheel sensor (WP 0125). Check for continuity. Disconnect connector X171 and check for continuity to ground at pins 4 and 12 (Figure 5 (Volume 2, WP 0272)). There should not be continuity to ground. a. b. c. If continuity to ground is found at pin 4, disconnect wire BU from connector X167 pin 4 and recheck (Figure 5 (Volume 2, WP 0272)). If continuity to ground is found at pin 12, disconnect wire OR from connector X167 pin 12 and recheck (Figure 5 (Volume 2, WP 0272)). Replace grounded X171 to X167 cable (Volume 2, WP 0267).

5.

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ELECTRONIC CONTROL UNIT (ECU) SUPPLY VOLTAGE TROUBLESHOOTING - Continued CORRECTIVE ACTION - Continued 6. Check for continuity. Disconnect all of the numbered wires from connector X167 that go to the front wheel sensors and check each one for continuity to ground (Figure 5 (Volume 2, WP 0272)). If continuity to ground is found at any numbered wire, determine which wheel sensor it belongs to. Replace grounded wheel sensor (WP 0125). Check for continuity. Disconnect connector X170 and X171. Disconnect ECU (792) pins 138, 139, 140 and 141. Check wires A1714, A17112 (Figure 5 (Volume 2, WP 0272)), A1704, and A17012 (Figure 5 (Volume 2, WP 0272)) for continuity to ground. a. b. c. d. SYMPTOM Replace grounded wire. Repair or replace damaged connector (Volume 2, WP 0267). Replace damaged ECU (792) terminal board (WP 0100). Replace ECU (792) (WP 0100).

7.

ERROR CODE 454 MALFUNCTION Wheel Sensor Supply Voltage Out of Range (RT 240V1R, RT 240V2 and RT 240V3). CORRECTIVE ACTION 1. Check for voltage (5V) at connector X171 between pins 1 and 3 and 9 and 11 (Figure 5 (Volume 2, WP 0272)). a. b. c. d. 2. If voltage (5V) is not found, perform the following checks: Disconnect connector X170 and recheck for voltage at X171 between pins 1 and 3 and 9 and 11. If voltage (5V) is still not found, perform Step 2. If voltage (5V) returns after disconnecting X170, perform Step 3.

Check for voltage (5V) at connector X170 between pins 1 and 3, and 9 and 11 (Figure 5 (Volume 2, WP 0272)). a. b. c. If voltage (5V) is not found, perform the following checks: Disconnect connector X171 and recheck for voltage at X170 between pins 1 and 3, and 9 and 11. If voltage (5V) is still not found, perform Step 5.

3.

Check for continuity. Disconnect connector X170 and check for continuity to ground at pins 1 and 9 (Figure 5 (Volume 2, WP 0272)). There should not be continuity to ground. a. If continuity to ground is found at pin 1, disconnect wire GY from connector X192 pin 1 and recheck (Figure 5 (Volume 2, WP 0272)).

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ELECTRONIC CONTROL UNIT (ECU) SUPPLY VOLTAGE TROUBLESHOOTING - Continued CORRECTIVE ACTION - Continued b. c. 4. If continuity to ground is found at pin 9, disconnect wire BN from connector X192 pin 9 and recheck (Figure 5 (Volume 2, WP 0272)). Replace grounded X170 to X192 cable (Volume 2, WP 0267).

Check for continuity. Disconnect all of the numbered wires from connector X192 and check each one for continuity to ground (Figure 5 (Volume 2, WP 0272)). If continuity to ground is found at any numbered wire, determine which wheel sensor it belongs to. Replace grounded wheel sensor (WP 0125). Check for continuity. Disconnect connector X171 and check for continuity to ground at pins 1 and 9 (Figure 5 (Volume 2, WP 0272)). There should not be continuity to ground. a. b. c. If continuity to ground is found at pin 9, disconnect wire BN from connector X167 pin 12 and recheck (Figure 5 (Volume 2, WP 0272)). If continuity to ground is found at pin 9, disconnect wire BN from connector X167 pin 12 and recheck Figure 5 (Volume 2, WP 0272)). Replace grounded X171 to X167 cable (Volume 2, WP 0267).

5.

6.

Check continuity. Disconnect all of the numbered wires from connector X167 that go to the front wheel sensors and check each one for continuity to ground (Figure 5 (Volume 2, WP 0272)). If continuity to ground is found at any numbered wire, determine which wheel sensor it belongs to. Replace grounded wheel sensor (WP 0125). Check for continuity. Disconnect connector X170 and X171. Disconnect ECU (792) pins 86, 87, 88, and 89. Check wires A1711, A1719 (Figure 5 (Volume 2, WP 0272)), A1701, and A1709 (Figure 5 (Volume 2, WP 0272)) for continuity to ground. a. b. c. d. Replace grounded wire. Repair or replace damaged connector (Volume 2, WP 0267). Replace damaged ECU (792) terminal board (WP 0100). Replace ECU (792) (WP 0100).

7.

SYMPTOM

ERROR CODE 811 MALFUNCTION Voltage Supply Too Low for Transmission ECU (793). CORRECTIVE ACTION 1. Ensure circuit breakers F27 and F28 are not tripped. Reset circuit breaker(s).

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0015

ELECTRONIC CONTROL UNIT (ECU) SUPPLY VOLTAGE TROUBLESHOOTING - Continued CORRECTIVE ACTION - Continued 2. Check for voltage (22V to 26V) at connector X174 at pins 1 and 2 with the engine running (Figure 5 (Volume 2, WP 0272)). a. b. c. d. 3. If voltage is found but less than 18V, check the condition and charge of the vehicle batteries. Check voltage output of alternator at either NATO slave receptacle. Charge or replace discharged vehicle batteries (WP 0128) and (WP 0129). Replace defective alternator (WP 0091) and Alternator Drive Belt Maintenance (WP 0092).

Check for voltage (22V to 26V) at connector 174 at pins 1 and 2 with the engine running (Figure 5 (Volume 2, WP 0272)). a. b. c. d. If no voltage (22V to 26V) is found at either pin, check circuit breakers F27 and F28 and continuity of wires A471 and A472 (Figure 4 (Volume 2, WP 0272)). Replace damaged or defective circuit breaker (WP 0103). Repair or replace damaged connector (Volume 2, WP 0267). Replace damaged or open wire.

4.

Check for voltage (22V to 26V) at ECU (793) at pins 23, 45, and 68 with the ignition ON (Figure 4 (Volume 2, WP 0272)). a. b. c. d. If voltage (22V to 26V) is found, replace ECU (793) (WP 0100). If no voltage (22V to 26V) is found at any one pin, check continuity of wires A1741A, A1741B, and A1742A (Figure 4 (Volume 2, WP 0272)). Repair or replace damaged connector (Volume 2, WP 0267). Replace damaged or open wire.

SYMPTOM

ERROR CODE 812 MALFUNCTION Voltage Supply Too High for Transmission ECU (793). CORRECTIVE ACTION Check output voltage from alternator. If output voltage is higher than 26V, replace alternator (WP 0091).

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0015

ELECTRONIC CONTROL UNIT (ECU) SUPPLY VOLTAGE TROUBLESHOOTING - Continued

SYMPTOM

ERROR CODE 813 MALFUNCTION Voltage Failure at Transmission Gearshift Valve Supply. CORRECTIVE ACTION 1. 2. Ensure circuit breaker F27 is not tripped. Reset circuit breakers. Check for voltage (22V to 26V) at connector X174 at pin 1 with the engine running (Figure 5 (Volume 2, WP 0272)). a. b. c. d. 3. If no voltage (22V to 26V) is found, check circuit breaker F27 and continuity of wires A471 (Figure 8 (Volume 2, WP 0272)) and 471 (Figure 4 (Volume 2, WP 0272)) Replace damaged or defective circuit breaker (WP 0103). Repair or replace damaged connector (Volume 2, WP 0267). Replace damaged or open wire.

Disconnect ECU (793) and inspect ECU and connector pins for damage. Check for voltage (22V to 26V) on the ECU (793) connector at pins 23 and 68 with the ignition ON (Figure 4 (Volume 2, WP 0272)). a. b. c. d. If no voltage (22V to 26V) is found at any one pin, check continuity of wires A1471A and A1741B (Figure 4 (Volume 2, WP 0272)). Repair or replace damaged connector (Volume 2, WP 0267). Replace damaged or open wire. If voltage (22V to 26V) is found, replace ECU (793) (WP 0100).

SYMPTOM ERROR CODE 814 MALFUNCTION Voltage Failure at Transmission Gearshift Valve Power Supply. CORRECTIVE ACTION Perform troubleshooting procedure for ERROR CODE 813 in this work package. END OF WORK PACKAGE

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FIELD MAINTENANCE INPUT AND OUTPUT SIGNALS FOR STEERING ECU (792) TROUBLESHOOTING

INITIAL SETUP: Tools and Special Tools Multimeter (Volume 2, WP 0277, Table 1, Item 52) References TM 10-3930-675-10 WP 0005 WP 0032 WP 0094 WP 0100 References (cont.) WP 0101 WP 0103 WP 0105 Volume 2, WP 0169 Volume 2, WP 0170 Volume 2, WP 0179 Volume 2, WP 0228 Volume 2, WP 0267 Volume 2, WP 0272

NOTE
Refer to Troubleshooting Symptom Index (WP 0005) for additional troubleshooting guidance, information, and illustrations that locate critical components. TROUBLESHOOTING PROCEDURE INPUT AND OUTPUT SIGNALS FOR STEERING ECU (792) TROUBLESHOOTING SYMPTOM

ERROR CODE 350 MALFUNCTION Right Front Wheel Valve Solenoid Error. CORRECTIVE ACTION Perform troubleshooting procedure for ERROR CODE 329 (WP 0032).

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INPUT AND OUTPUT SIGNALS FOR STEERING ECU (792) TROUBLESHOOTING - Continued

SYMPTOM

ERROR CODE 351 MALFUNCTION Right Rear Wheel Valve Solenoid Error. CORRECTIVE ACTION

NOTE
ERROR CODE 351 activates when the resistance of the solenoid or circuit is out of range from the preset value. This ERROR CODE is programmed for RT 240V2 and RT 204V3 vehicles only. Perform troubleshooting procedure for ERROR CODE 330 (WP 0032). SYMPTOM

ERROR CODE 352 MALFUNCTION Left Rear Wheel Valve Solenoid Error. CORRECTIVE ACTION

NOTE
ERROR CODE 352 activates when the resistance of the solenoid or circuit is out of range from the preset value. This ERROR CODE is programmed for RT 240V2 and RT 204V3 vehicles only. Perform troubleshooting procedure for ERROR CODE 331 (WP 0032).

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INPUT AND OUTPUT SIGNALS FOR STEERING ECU (792) TROUBLESHOOTING - Continued

SYMPTOM

ERROR CODE 353 MALFUNCTION Left Front Wheel Valve Solenoid Error. CORRECTIVE ACTION

NOTE
ERROR CODE 353 activates when the resistance of the solenoid or circuit is out of range from the preset value. This ERROR CODE is programmed for RT 240V2 and RT 204V3 vehicles only. Perform troubleshooting procedure for error code 332 (WP 0032). SYMPTOM

ERROR CODE 354 MALFUNCTION Right Front Wheel Valve Solenoid Error. CORRECTIVE ACTION

NOTE
ERROR CODE 354 activates when the solenoid current control initialization fails. This code typically is activated after ECU (792) has been replaced. This ERROR CODE is programmed for RT 240V2 and RT 204V3 vehicles only. Press reset. If recurring ERROR CODE activates, replace ECU (792) (WP 0100).

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INPUT AND OUTPUT SIGNALS FOR STEERING ECU (792) TROUBLESHOOTING - Continued

SYMPTOM

ERROR CODE 355 MALFUNCTION Right Front Wheel Valve Solenoid Error. CORRECTIVE ACTION

NOTE
ERROR CODE 355 activates when the solenoid current control initialization fails. This code typically is activated after ECU (792) has been replaced. This ERROR CODE is programmed for RT 240V2 and RT 204V3 vehicles only. Press reset. If recurring ERROR CODE activates, replace ECU (792) (WP 0100). SYMPTOM

ERROR CODE 356 MALFUNCTION Left Rear Wheel Valve Solenoid Error. CORRECTIVE ACTION

NOTE
ERROR CODE 356 activates when the solenoid current control initialization fails. This code typically is activated after ECU (792) has been replaced. This ERROR CODE is programmed for RT 240V2 and RT 204V3 vehicles only. Press reset. If recurring ERROR CODE activates, replace ECU (792) (WP 0100).

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INPUT AND OUTPUT SIGNALS FOR STEERING ECU (792) TROUBLESHOOTING - Continued

SYMPTOM

ERROR CODE 357 MALFUNCTION Right Front Wheel Valve Solenoid Error. CORRECTIVE ACTION

NOTE
ERROR CODE 357 activates when the solenoid current control initialization fails. This code typically is activated after ECU (792) has been replaced. This ERROR CODE is programmed for RT 240V2 and RT 204V3 vehicles only. Press reset. If recurring ERROR CODE activates, replace ECU (792) (WP 0100). SYMPTOM

ERROR CODE 399 MALFUNCTION EEPROM Parameter Error in ECU (792). CORRECTIVE ACTION

NOTE
ERROR CODE 399 activates when one or more EEPROM parameter values are out of range. This ERROR CODE is programmed for RT 240V2 and RT 204V3 vehicles only. Press reset. If recurring ERROR CODE activates, replace ECU (792) Electronic Control Units (ECU) Replacement (WP 0100).

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INPUT AND OUTPUT SIGNALS FOR STEERING ECU (792) TROUBLESHOOTING - Continued

SYMPTOM

ERROR CODE 401 MALFUNCTION Transmission Neutral Signal from Steering ECU (792) Short Circuit Failure. CORRECTIVE ACTION Check for continuity to ground on wire A79344 between steering ECU (792) pin 71 (Figure 5 (Volume 2, WP 0272)) and transmission ECU (793) pin 44 (Figure 4 (Volume 2, WP 0272)). If continuity is present, replace wire A79344. SYMPTOM

ERROR CODE 404 MALFUNCTION 2WD Steering Control Lamp, Short Circuit Failure. CORRECTIVE ACTION

NOTE
ERROR CODE 404 is an information type ERROR CODE. It may not activate for the operator. The operator may report the indicator light is not working. Enter "DIAG STEERING 2(16)" in the Diagnostic menu to verify the code or enable the information type code in the Initialization menu. 1. 2. Inspect the 2-wheel drive selection switch for damage. Replace damaged steering selection switch (WP 0094). Inspect light bulb. Remove the screws from the menu selection button panel on the steering column console. Lift the panel to access the 2-wheel drive selection button. Pull the light socket down and out from the console. Remove the light bulb and inspect (WP 0094). Replace damaged or shorted light bulb (WP 0094). Disconnect connector X177 located in the middle panel. Should not have continuity to ground. Check for continuity to ground on the loose part of X177 at pin 1 (Figure 5 (Volume 2, WP 0272)). a. b. c. If continuity to ground is found, disconnect X153 and recheck. If continuity to ground is still found, check wires 1601 and A1531 for continuity to ground (Figure 5 (Volume 2, WP 0272)). Replace grounded X177 to X160 cable or grounded wire A1531.

3.

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INPUT AND OUTPUT SIGNALS FOR STEERING ECU (792) TROUBLESHOOTING - Continued CORRECTIVE ACTION - Continued 4. Check for continuity to ground on the loose part of X153 at pin 1 (Figure 5 (Volume 2, WP 0272)). There should not be continuity to ground. a. b. c. 5. If continuity to ground is found, replace the X153 to steering column harness (WP 0094). If continuity to ground is not found, check wire A1771 for continuity to ground (Figure 5 (Volume 2, WP 0272)). Replace grounded wire A1771.

Check ECU (792) pin 68 for connection or damage (Figure 5 (Volume 2, WP 0272)). a. b. Replace damaged ECU (792) terminal board (WP 0100). Replace ECU (792) (WP 0100).

SYMPTOM

ERROR CODE 405 MALFUNCTION 4WD Steering Control Lamp, Short Circuit Failure. CORRECTIVE ACTION

NOTE
ERROR CODE 405 is an information type ERROR CODE. It may not activate for the operator. The operator may report the indicator light is not working. Enter "DIAG STEERING 2(16)" in the Diagnostic menu to verify the code or enable the information type code in the Initialization menu. 1. 2. Inspect the 4-wheel drive selection switch for damage. Replace damaged steering selection switch (WP 0094). Inspect light bulb. Remove the screws from the menu selection button panel on the steering column console. Lift the panel to access the 4-wheel drive selection button. Pull the light socket down and out from the console. Replace damaged or shorted light bulb (WP 0094). Check for continuity. Disconnect connector X177 located in the middle panel. Check for continuity to ground on the loose part of X177 at pin 2 (Figure 5 (Volume 2, WP 0272)). There should not be continuity to ground. a. b. c. d. If continuity to ground is found, disconnect X153 and recheck. If continuity to ground is still found, check wires 1602 and A1532 for continuity to ground (Figure 5 (Volume 2, WP 0272)). Replace grounded X177 to X160 cable or grounded wire A1531. Replace grounded X177 to X160 cable or grounded wire A1532.

3.

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INPUT AND OUTPUT SIGNALS FOR STEERING ECU (792) TROUBLESHOOTING - Continued CORRECTIVE ACTION - Continued 4. Check for continuity to ground on the loose part of X153 at pin 2 (Figure 5 (Volume 2, WP 0272)). There should not be continuity to ground. a. b. c. 5. If continuity to ground is found, replace the X153 to steering column harness (WP 0094). If continuity to ground is not found, check wire A1772 for continuity to ground (Figure 5 (Volume 2, WP 0272)). Replace grounded wire A1772.

Check ECU (792) pin 67 for connection or damage (Figure 5 (Volume 2, WP 0272)). a. b. Replace damaged ECU (792) terminal board (WP 0100). Replace ECU (792) (WP 0100).

SYMPTOM

ERROR CODE 406 MALFUNCTION Crab Steering Control Lamp, Short Circuit Failure. CORRECTIVE ACTION

NOTE
ERROR CODE 406 is an information type ERROR CODE. It may not activate for the operator. The operator may report the indicator light is not working. Enter "DIAG STEERING 2(16)" in the Diagnostic menu to verify the code or enable the information type codes in the initialization menu. 1. 2. Inspect the crab steering selection switch for damage. Replace damaged steering selection switch (WP 0094). Inspect light bulb. Remove the screws from the menu selection button panel on the steering column console. Lift the panel to access the crab steering selection button. Pull the light socket down and out from the console. Replace damaged or shorted light bulb (WP 0094). Check for continuity. Disconnect connector X177 located in the middle panel. Check for continuity to ground on the loose part of X177 at pin 3 (Figure 5 (Volume 2, WP 0272)). There should not be continuity to ground. a. b. c. 4. If continuity to ground is found, disconnect X153 and recheck. If continuity to ground is still found, check wires 1603 and A1533 for continuity to ground (Figure 5 (Volume 2, WP 0272)). Replace grounded X177 to X160 cable or grounded wire A 1533.

3.

Check for continuity to ground on the loose part of X153 at pin 3 (Figure 5 (Volume 2, WP 0272)). There should not be continuity to ground. a. If continuity to ground is found, replace the X153 to steering column harness (WP 0094).

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INPUT AND OUTPUT SIGNALS FOR STEERING ECU (792) TROUBLESHOOTING - Continued CORRECTIVE ACTION - Continued b. c. 5. If continuity to ground is not found, check wire A1733 for continuity to ground (Figure 5 (Volume 2, WP 0272)). Replace grounded wire A1733.

Check ECU (792) pin 66 for connection or damage (Figure 5 (Volume 2, WP 0272)). a. b. Replace damaged ECU (792) terminal board (WP 0100). Replace ECU (792) (WP 0100).

SYMPTOM

ERROR CODE 408 MALFUNCTION Unlocked Twistlock Control Lamp, Short Circuit Failure. CORRECTIVE ACTION

NOTE
ERROR CODE 408 is an information type ERROR CODE. It may not activate for the operator. The operator may report the indicator light is not working. Enter "DIAG STEERING 2(16)" in the Diagnostic menu to verify the code or enable the information type codes in the initialization menu. 1. 2. Inspect the twistlock indicator lights for damage. Replace damaged twistlock indicator light(s) (WP 0094). Check light fixtures. Access twistlock indicator lights (WP 0094) in the steering column console. Inspect twistlock indicator light sockets, bulbs, and wiring. Replace damaged or shorted light bulb, socket, or wiring (WP 0094). Check for continuity. Disconnect connector X177 located in the middle panel. Check for continuity to ground on the loose part of X177 at pin 4 (Figure 5 (Volume 2, WP 0272)). There should not be continuity to ground. a. b. c. d. 4. If continuity to ground is found, disconnect X153 and recheck. If continuity to ground is still found, check wires 1604 and A1534 for continuity to ground (Figure 5 (Volume 2, WP 0272)). Replace grounded X177 to X160 cable or grounded wire A1534. Replace grounded X177 to X160 cable or grounded wire A 1533.

3.

Check for continuity to ground on the loose part of X153 at pin 4 (Figure 5 (Volume 2, WP 0272)). There should not be continuity to ground. a. b. c. If continuity to ground is found, replace the X153 to steering column harness (WP 0094). If continuity to ground is not found, check wire A1774 for continuity to ground (Figure 5 (Volume 2, WP 0272)). Replace grounded wire A1774.

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0016

INPUT AND OUTPUT SIGNALS FOR STEERING ECU (792) TROUBLESHOOTING - Continued CORRECTIVE ACTION - Continued 5. Check ECU (792) pin 64 for connection or damage (Figure 5 (Volume 2, WP 0272)). a. b. SYMPTOM Replace damaged ECU (792) terminal board (WP 0100). Replace ECU (792) (WP 0100).

ERROR CODE 409 MALFUNCTION Locked Twistlock Control Lamp, Short Circuit Failure. CORRECTIVE ACTION

NOTE
ERROR CODE 409 is an information type ERROR CODE. It may not activate for the operator. The operator may report the indicator light is not working. Enter "DIAG STEERING 2(16)" in the Diagnostic menu to verify the code or enable the information type codes in the initialization menu. 1. 2. Inspect the twistlock indicator lights for damage. Replace damaged twistlock indicator light(s) (WP 0094). Check light fixtures. Access twistlock indicator lights (WP 0094) in the steering column console. Inspect twistlock indicator light sockets, bulbs, and wiring. Replace damaged or shorted light bulb, socket, or wiring (WP 0094). Check for continuity. Disconnect connector X177 located in the middle panel. Check for continuity to ground on the loose part of X177 at pin 6 (Figure 5 (Volume 2, WP 0272)). There should not be continuity to ground. a. b. c. 4. If continuity to ground is found, disconnect X153 and recheck. If continuity to ground is still found, check wires 1606 and A1536 for continuity to ground (Figure 5 (Volume 2, WP 0272)). Replace grounded X177 to X160 cable or grounded wire A1536.

3.

Check for continuity to ground on the loose part of X153 at pin 6 (Figure 5 (Volume 2, WP 0272)). There should not be continuity to ground. a. b. c. If continuity to ground is found, replace the X153 to steering column harness (WP 0094). If continuity to ground is not found, check wire A1776 for continuity to ground (Figure 5 (Volume 2, WP 0272)). Replace grounded wire A1776.

5.

Check ECU (792) pin 63 for connection or damage (Figure 5 (Volume 2, WP 0272)). a. b. Replace damaged ECU (792) terminal board (WP 0100). Replace ECU (792) (WP 0100).

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0016

INPUT AND OUTPUT SIGNALS FOR STEERING ECU (792) TROUBLESHOOTING - Continued

SYMPTOM

ERROR CODE 410 MALFUNCTION Alignment Control Lamp, Short Circuit Failure. CORRECTIVE ACTION

NOTE
ERROR CODE 410 is an information type ERROR CODE. It may not activate for the operator. The operator may report the indicator light is not working. Enter "DIAG STEERING 2(16)" in the Diagnostic menu to verify the code or enable the information type codes in the initialization menu. 1. 2. Inspect the twistlock indicator lights for damage. Replace damaged twistlock indicator light(s) (WP 0094). Check light fixtures. Access twistlock indicator lights (WP 0094) in the steering column console. Inspect twistlock indicator light sockets, bulbs, and wiring. Replace damaged or shorted light bulb, socket, or wiring (WP 0094). Check for continuity. Disconnect connector X177 located in the middle panel. Check for continuity to ground on the loose part of X177 at pin 5 (Figure 5 (Volume 2, WP 0272)). There should not be continuity to ground. a. b. c. 4. If continuity to ground is found, disconnect X153 and recheck. If continuity to ground is still found, check wires 1605 and A1535 for continuity to ground (Figure 5 (Volume 2, WP 0272)). Replace grounded X177 to X160 cable or grounded wire A1535.

3.

Check for continuity to ground on the loose part of X153 at pin 5 (Figure 5 (Volume 2, WP 0272)). There should not be continuity to ground. a. b. c. If continuity to ground is found, replace the X153 to steering column harness (WP 0094). If continuity to ground is not found, check wire A1775 for continuity to ground (Figure 5 (Volume 2, WP 0272)). Replace grounded wire A1775.

5.

Check ECU (792) pin 62 for connection or damage (Figure 5 (Volume 2, WP 0272)). a. b. Replace damaged ECU (792) terminal board (WP 0100). Replace ECU (792) (WP 0100).

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0016

INPUT AND OUTPUT SIGNALS FOR STEERING ECU (792) TROUBLESHOOTING - Continued

SYMPTOM

ERROR CODE 412 MALFUNCTION Autolube Pump Control, Short Circuit Failure (RT 240V2/3 only). CORRECTIVE ACTION

NOTE
ERROR CODE 412 is an information type ERROR CODE. It may not activate for the operator. The operator may report the auto lube pump is not working. Enter "DIAG STEERING 2(16)" in the Diagnostic menu to verify the code or enable the information type codes in the initialization menu. 1. Test relay. Remove the plastic cover from the right rear of the cab to access the cab distribution box (WP 0103). Open the cab distribution box to access the relay boards. Remove relay 3018 and test (Volume 2, WP 0267). Replace relay if resistance between terminals 85 and 86 is not 290 to 350 Ohms. Check for continuity. Disconnect connector X174B located in the middle panel. Check for continuity to ground on the loose part of X174B at pin 2. There should not be continuity to ground. a. b. c. 3. If continuity to ground is found, disconnect X47 and recheck. If continuity to ground is still found, check wire 476 for continuity to ground (Figure 5 (Volume 2, WP 0272)). Replace grounded X174B to X47 cable (Volume 2, WP 0267).

2.

Check for continuity. Disconnect connector X47 and connector XK1 located on one of the relay boards. Check for continuity to ground on the loose part of XK1 at pin 8. There should not be continuity to ground. a. b. c. If continuity to ground is found, replace wire A476. If continuity to ground is not found, check wire A174B2 for continuity to ground (Figure 17 (Volume 2, WP 0272)). Replace grounded wire A174B2.

4.

Check ECU (792) pin 60 for connection or damage (Figure 5 (Volume 2, WP 0272)). a. b. Replace damaged ECU (792) terminal board (WP 0100). Replace ECU (792) (WP 0100).

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0016

INPUT AND OUTPUT SIGNALS FOR STEERING ECU (792) TROUBLESHOOTING - Continued

SYMPTOM

ERROR CODE 413 MALFUNCTION Boom Folding Supply Valve, Short Circuit Failure. CORRECTIVE ACTION

NOTE
ERROR CODE 413 is an information type ERROR CODE. It may not activate for the operator. The operator may report the boom folding system is not working. Enter "DIAG STEERING 2(16)" in the Diagnostic menu to verify the code or enable the information type codes in the initialization menu. 1. Test for resistance. Open the door to the remote hydraulic compartment. Locate the 6043 boom folding supply valve on the left side wall. Disconnect the connector and check the resistance of the solenoid coil. Resistance should be 40 to 50 Ohms. Replace 643 boom folding supply valve if damaged or resistance is not as specified (Volume 2, WP 0228). Check for continuity. Disconnect connector X195 located in the middle panel and disconnect the 6043 boom folding supply valve. Check for continuity to ground on the loose part of X195 at pin 8 (Figure 7 (Volume 2, WP 0272)). There should not be continuity to ground. a. b. c. 3. If continuity to ground is found, move the cab to the transport position to access X198 under the cover plate. Disconnect X198 pin 9 wire VT and recheck. If continuity to ground is still found, check wire VT for continuity to ground (Figure 7 (Volume 2, WP 0272)). Replace grounded X195 to X198 cable (Volume 2, WP 0267).

2.

Check for continuity. Disconnect connector X198 pin 9 wire GY and disconnect the 6043 boom folding supply valve. Check wire GY for continuity to ground (Figure 7 (Volume 2, WP 0272)). There should not be continuity to ground. a. b. c. If continuity to ground is found, replace wire X198 to 6043 cable (Volume 2, WP 0267). If continuity to ground is not found, check wire A195B for continuity to ground (Figure 7 (Volume 2, WP 0272)). Replace grounded wire A195B.

4.

Check ECU (792) pin 59 for connection or damage (Figure 7 (Volume 2, WP 0272)). a. b. Replace damaged ECU (792) terminal board (WP 0100). Replace ECU (792) (WP 0100).

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0016

INPUT AND OUTPUT SIGNALS FOR STEERING ECU (792) TROUBLESHOOTING - Continued

SYMPTOM

ERROR CODE 415 MALFUNCTION Drag Restriction, Short Circuit Failure (RT 240V1R, RT 240V2 and RT 240V3 only). CORRECTIVE ACTION 1. Check continuity. Disconnect X174B located in the middle panel behind the operators seat. Check the diode for continuity of the loose part of X174B between pins 14 and 15. There should be continuity from pin 15 to pin 14 and not from pin 14 to pin 15 (Figure 4 (Volume 2, WP 0272)). Replace the diode if continuity is found in both directions. Check wire A174B15 for continuity to ground. There should not be continuity to ground (Figure 5 (Volume 2, WP 0272)). a. b. 3. If continuity to ground is found, replace wire A174B15. Repair or replace damaged connector (Volume 2, WP 0267).

2.

Check ECU (792) pin 57 for connection or damage. a. b. Replace damaged ECU (792) terminal board. Replace ECU (792) (WP 0100).

SYMPTOM

ERROR CODE 416 MALFUNCTION Steering Pressure Switch, Circuit Input Error. CORRECTIVE ACTION

NOTE
ERROR CODE 416 is an information type ERROR CODE. It may not activate for the operator. Enter "DIAG STEERING 2(16)" in the Diagnostic menu to verify the code or enable the information type codes in the initialization menu. Input error type codes can be activated if the voltage input is not stable due to a bad connection. ERROR CODE 340 may be active with this ERROR CODE. 1. Place the cab in the transport position (TM 10-3930-675-10) and remove the hydraulic pump access cover. Inspect the steering pressure switch (245) mounted on the steering valve for damage and connection. Replace damaged steering pressure switch (Volume 2, WP 0170).

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0016

INPUT AND OUTPUT SIGNALS FOR STEERING ECU (792) TROUBLESHOOTING - Continued CORRECTIVE ACTION - Continued 2. Check connectors X47, X174, and X197 for connection or damage (RT 240V1 only). a. b. c. 3. Repair or replace damaged connector (Volume 2, WP 0267). If connectors are found to be in good condition, check wires A473, 473, A1743B, 1973, and 1974 for continuity (Figure 5 (Volume 2, WP 0272)). Replace or repair open or damaged wire.

Check connector X47, X174B, and X197 for connection or damage (RT 240V1R, RT 240V2 and RT 240V3 only). a. b. c. Repair or replace damaged connector (Volume 2, WP 0267). If connectors are found to be in good condition, check wires A475, 475, A174B1A, 1973, and 1974 for continuity (Figure 5 (Volume 2, WP 0272)) Replace or repair open or damaged wire.

4.

Check ECU (792) pin 49 for connection or damage (Figure 5 (Volume 2, WP 0272)). a. b. Check wire A1974 for continuity (Figure 5 (Volume 2, WP 0272)). Replace damaged ECU (792) terminal board (WP 0100).

5.

Check wire. Disconnect wire A1974 from ECU (792) and recheck for active 416 ERROR CODE. Replace ECU (792) (WP 0100) if ERROR CODE 416 is still active.

SYMPTOM

ERROR CODE 418 MALFUNCTION 2WD Steering Selection Switch, Circuit Input Error. CORRECTIVE ACTION

NOTE
ERROR CODE 418 is an information type ERROR CODE. It may not activate for the operator. Enter "DIAG STEERING 2(16)" in the Diagnostic menu to verify the code or enable the information type codes in the initialization menu. Input error type codes can be activated if the voltage input is not stable due to a bad connection. 1. 2. Inspect the 2WD steering selection switch for damage and connection. Replace damaged 2WD steering selection switch (WP 0101). Inspect connectors X177, X160, and X153 for connection or damage. a. b. c. Repair or replace damaged connector (Volume 2, WP 0267). If connectors are found to be in good condition, check wires 15313, A15313, and 16013 (Figure 5 (Volume 2, WP 0272)). Replace or repair open or damaged wire.

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0016

INPUT AND OUTPUT SIGNALS FOR STEERING ECU (792) TROUBLESHOOTING - Continued CORRECTIVE ACTION - Continued 3. Check ECU (792) pin 47 for connection or damage (Figure 5 (Volume 2, WP 0272)). a. b. 4. Check wire A17713 for continuity (Figure 5 (Volume 2, WP 0272)). Replace damaged ECU (792) terminal board (WP 0100).

Check wire connection. Disconnect wire A17713 from ECU (792) and recheck for active 418 ERROR CODE. Replace ECU (792) (WP 0100) if ERROR CODE 418 is still active.

SYMPTOM

ERROR CODE 419 MALFUNCTION 4WD Steering Selection Switch, Circuit Failure. CORRECTIVE ACTION

NOTE
ERROR CODE 419 is an information type ERROR CODE. It may not activate for the operator. Enter "DIAG STEERING 2(16)" in the Diagnostic menu to verify the code or enable the information type codes in the initialization menu. Input error type codes can be activated if the voltage input is not stable due to a bad connection. 1. 2. Inspect the 4WD steering selection switch for damage and connection. Replace damaged 4WD steering switch (WP 0101). Inspect connectors X177, X160, and X153 for connection or damage. a. b. c. 3. Repair or replace damaged connector (Volume 2, WP 0267). If connectors are found to be in good condition, check wires 1529C, 15314, A15314, and 16014 (Figure 5 (Volume 2, WP 0272)) for continuity. Replace or repair open or damaged wire.

Check ECU (792) pin 46 for connection or damage (Figure 5 (Volume 2, WP 0272)). a. b. Check wire A17714 for continuity (Figure 5 (Volume 2, WP 0272)). Replace damaged ECU (792) terminal board (WP 0100)).

4.

Check wire connection. Disconnect wire A17714 from ECU (792) and recheck for active 419 ERROR CODE. Replace ECU (792) (WP 0100) if ERROR CODE 419 is still active.

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0016

INPUT AND OUTPUT SIGNALS FOR STEERING ECU (792) TROUBLESHOOTING - Continued

SYMPTOM

ERROR CODE 420 MALFUNCTION Crab Steering Selection Switch, Circuit Failure. CORRECTIVE ACTION

NOTE
ERROR CODE 420 is an information type ERROR CODE. It may not activate for the operator. Enter "DIAG STEERING 2(16)" in the Diagnostic menu to verify the code or enable the information type codes in the initialization menu. Input error type codes can be activated if the voltage input is not stable due to a bad connection. 1. 2. Inspect the crab steering selection switch for damage and connection. Replace damaged crab steering switch (WP 0101). Inspect connectors X177, X160, and X153 for connection or damage. a. b. c. d. 3. Inspect connectors X177, X160, and X153 for connection or damage. Repair or replace damaged connector (Volume 2, WP 0267). If connectors are found to be in good condition, check wires 1529D, 15315, A15315, and 16015 (Figure 5 (Volume 2, WP 0272)) for continuity. Repair or replace open or damaged wire.

Check ECU (792) pin 45 for connection or damage (Figure 5 (Volume 2, WP 0272)). a. b. Check wire A17715 for continuity (Figure 5 (Volume 2, WP 0272)). Replace damaged ECU (792) terminal board (WP 0100).

4.

Check wire connection. Disconnect wire A17715 from ECU (792) and recheck for active 420 ERROR CODE. Replace ECU (792) (WP 0100) if ERROR CODE 420 is still active.

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0016

INPUT AND OUTPUT SIGNALS FOR STEERING ECU (792) TROUBLESHOOTING - Continued

SYMPTOM

ERROR CODE 422 MALFUNCTION Cab in Transport Proximity Switch, Circuit Input Error. CORRECTIVE ACTION

NOTE
ERROR CODE 422 is an information type ERROR CODE. It may not activate for the operator. Enter "DIAG STEERING 2(16)" in the Diagnostic menu to verify the code or enable the information type codes in the initialization menu. Input error type codes can be activated if the voltage input is not stable due to a bad connection. 1. 2. Inspect the cab transport proximity switch (7210) located at the right rear of cab for damage. Replace damaged cab in transport proximity switch (WP 0105). Check for proper operation. Place cab in transport position (TM 10-3930-675-10) and check for proper gap and engagement of proximity switch against the frame. Proximity switch should not extend beyond the end of the protective enclosure. Adjust proximity switch or cab to obtain the proper gap (5 mm) (WP 0105) and (Volume 2, WP 0179). Inspect connectors X175, X195, A174, A47, and X174B (RT 240V1R, RT 240V2 and RT 240V3) for connection damage. a. b. Repair or replace damaged connector (Volume 2, WP 0267)). If connectors are found to be in good condition, check wires A1957A, A1957B, (Figure 7 (Volume 2, WP 0272)), A1743C, A1743D A174B1B and A174B1C (RT 240V1R, RT 240V2 and RT 240V3) (Figure 7 (Volume 2, WP 0272)) and A1743B, A1743C, A174B1A, A475, and 475 (RT 240V1R, RT 240V2 and RT 240V3) (Figure 5 (Volume 2, WP 0272)) for continuity. Replace or repair open or damaged wire.

3.

c. 4.

Check ECU (792) pin 43 for connection or damage (Figure 7 (Volume 2, WP 0272)). a. b. Check wire A1752 for continuity (Figure 7 (Volume 2, WP 0272)). Replace damaged ECU (792) terminal board (WP 0100)).

5.

Check wire connection. Disconnect wire A1752 from ECU (792) and recheck for active 422 ERROR CODE. a. b. Replace ECU (792) (WP 0100) if ERROR CODE 422 is still active. Replace proximity switch (7210) (WP 0105).

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0016

INPUT AND OUTPUT SIGNALS FOR STEERING ECU (792) TROUBLESHOOTING - Continued

SYMPTOM

ERROR CODE 423 MALFUNCTION Ether Start Switch, Circuit Failure. CORRECTIVE ACTION

NOTE
ERROR CODE 423 is an information type ERROR CODE. It may not activate for the operator. Enter "DIAG STEERING 2(16)" in the Diagnostic menu to verify the code or enable the information type codes in the initialization menu. Input error type codes can be activated if the voltage input is not stable due to a bad connection. 1. 2. Inspect the ether start switch for damage and connection. Replace damaged ether start switch (WP 0094). Inspect connectors X174, X47, and X67 for connection or damage. a. b. 3. Repair or replace damaged connector (Volume 2, WP 0267). If connectors are found to be in good condition, check wires 674, A479, and d479 (Figure 16 (Volume 2, WP 0272)) for continuity.

Check ECU (792) pin 42 for connection or damage (Figure 5 (Volume 2, WP 0272)). a. b. c. Check wire A17415 for continuity (Figure 5 (Volume 2, WP 0272)). Replace damaged ECU (792) terminal board (WP 0100). Replace or repair open or damaged wire (Volume 2, WP 0267).

4.

Check for wire connection. Disconnect wire A17415 from ECU (792) and recheck for active 423 ERROR CODE. Replace ECU (792) (WP 0100) if ERROR CODE 423 is still active.

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0016

INPUT AND OUTPUT SIGNALS FOR STEERING ECU (792) TROUBLESHOOTING - Continued

SYMPTOM

ERROR CODE 427 MALFUNCTION Tophandler Work Light Switch, Circuit Input Error. CORRECTIVE ACTION

NOTE
ERROR CODE 427 is an information type ERROR CODE. It may not activate for the operator. Enter "DIAG STEERING 2(16)" in the Diagnostic menu to verify the code or enable the information type codes in the initialization menu. Input error type codes can be activated if the voltage input is not stable due to a bad connection. 1. 2. Inspect tophandler work light switch for damage and connection. Replace damaged tophandler work light switch (WP 0094). Inspect connectors X174, X46, and X67 for connection or damage. a. b. c. 3. Repair or replace damaged connector (Volume 2, WP 0267). If connectors are found to be in good condition, check wires 679, A466 (Figure 15 (Volume 2, WP 0272)), and 466 (Figure 5 (Volume 2, WP 0272)) for continuity. Replace or repair open or damaged wire (Volume 2, WP 0267).

Check ECU (792) pin 102 for connection or damage (Figure 5 (Volume 2, WP 0272)). a. b. Check wire A17411 for continuity (Figure 5 (Volume 2, WP 0272)). Replace damaged ECU (792) terminal board (WP 0100).

4.

Check for wire connection. Disconnect wire A17411 from ECU (792) and recheck for active 427 ERROR CODE. Replace ECU (792) (WP 0100) if ERROR CODE 427 is still active.

SYMPTOM

ERROR CODE 440

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0016

INPUT AND OUTPUT SIGNALS FOR STEERING ECU (792) TROUBLESHOOTING - Continued MALFUNCTION Steering Wheel Sensor, Power Supply Error (RT 240V1R, RT 240V2 and RT 240V3 only). CORRECTIVE ACTION

NOTE
ERROR CODE 440 is an information type ERROR CODE. It may not activate for the operator. The operator may report the steering wheel has no resistance and does not stop at the full turning radius. Enter "DIAG STEERING 2(16)" in the Diagnostic menu to verify the code or enable the information type codes in the initialization menu. 1. Inspect the steering wheel sensor and connector cable located at the bottom of the steering column for damage. Replace damaged steering wheel sensor or connector cable (Volume 2, WP 0169). Disconnect the connector from the steering wheel sensor and connector X176 located in the middle panel behind the operators seat. Check each wire in the cable for continuity, continuity to ground, and for continuity between each wire (Figure 5 (Volume 2, WP 0272)). Replace damaged, grounded, or shorted steering wheel sensor to X176 cable (Volume 2, WP 0169). Check for continuity to ground or continuity between each wire on the mounted part of connector X176 for pins 1 through 8 (Figure 5 (Volume 2, WP 0272)). There should not be continuity to ground or continuity between wires. a. b. 4. Replace any grounded or shorted wire(s). Repair or replace damaged connector (Volume 2, WP 0267).

2.

3.

Check ECU (792) pins, 23, 40, 113, 96, 41, 38, 132, 97, and 56 for connection or damage (Figure 5 (Volume 2, WP 0272)). a. b. Replace damaged ECU (792) terminal board (WP 0100). Replace ECU (792) (WP 0100).

SYMPTOM

ERROR CODE 450 MALFUNCTION Temperature Inside Steering ECU (792) Above Critical Threshold [184F (85C)]. CORRECTIVE ACTION 1. 2. Check if temperature at steering ECU (792) is extremely high. If temperature is extremely high, allow ECU to cool down. Place ignition switch in OFF position for a minimum of 30 seconds, and then back in ON position. Replace steering ECU (792) if ERROR CODE is still present (WP 0100).

END OF WORK PACKAGE

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0017

FIELD MAINTENANCE ENGINE ELECTRONIC CONTROL UNIT (ECU) (794) TROUBLESHOOTING

INITIAL SETUP: Tools and Special Tools Lead, Test (Volume 2, WP 0277, Table 1, Item 47) Lead, Test (Volume 2, WP 0277, Table 1, Item 49) Multimeter (Volume 2, WP 0277, Table 1, Item 52) References WP 0005 References (cont.) WP 0078 WP 0099 WP 0100 WP 0118 Volume 2, WP 0267 Volume 2, WP 0272

NOTE
Refer to Troubleshooting Symptom Index (WP 0005) troubleshooting guidance, information, and illustrations that locate critical components. Refer also to illustration at end of work package for component location.

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TROUBLESHOOTING PROCEDURE ENGINE ELECTRONIC CONTROL UNIT (ECU) (794) TROUBLESHOOTING SYMPTOM

ERROR CODE 1187 MALFUNCTION Sensor Voltage Supply Failure. CORRECTIVE ACTION 1. 2. 3. Disconnect sensor harness from oil pressure/temperature sensor (WP 0118). Place ignition switch in ON position. Measure voltage from oil pressure/temperature sensor connector pin A to pin B. Voltage should be less than 4.5V. If voltage is not as specified, replace oil pressure/temperature sensor (WP 0118).

<4.5V USE TEST LEAD KIT P/N 3822758

T0124JCH

Figure 1. Oil Pressure/Temperature Sensor Voltage Test. 4. Place ignition switch in OFF position and disconnect sensor harness connector from engine ECU. a. Inspect engine harness and sensor connector for dirty, corroded, bent, broken, pushed back, and extended pins. Clean and repair connector(s) as required Electrical General Maintenance Instructions). Check engine harness and engine ECU connector for dirt or moisture in or on connector and for missing or damaged connector seals. Remove dirt and moisture from connector. Replace missing or damaged connector seals (Volume 2, WP 0267).

b.

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0017

ENGINE ELECTRONIC CONTROL UNIT (ECU) (794) TROUBLESHOOTING - Continued CORRECTIVE ACTION - Continued 5. Disconnect sensor harness and actuator harness from engine ECU. Place ignition switch to ON position. a. Measure voltage between engine ECU sensor port pin 18, pin 25, pin 45, and ground. Voltage should be 4.75 to 5.25V. If voltage is not as specified, replace engine ECU (WP 0099). Measure voltage between engine ECU actuator port pin 19 and pin 29 and ground. Voltage should be 4.75 to 5.25V. If voltage is not as specified, replace engine ECU (WP 0099).
ACTUATOR PORT: PINS 19 AND 29 TO ENGINE BLOCK GROUND 4.75-5.25V SENSOR PORT: PINS 18,25,45 TO ENGINE BLOCK GROUND 4.75-5.25V

b.

USE TEST LEAD KIT P/N 3822917


T0125JCH

Figure 2. Oil Pressure/Temperature Sensor Voltage Test.

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0017

ENGINE ELECTRONIC CONTROL UNIT (ECU) (794) TROUBLESHOOTING - Continued CORRECTIVE ACTION - Continued 6. Place ignition switch in OFF position. Disconnect sensor harness and actuator harness from engine ECU. a. Measure resistance from sensor harness connector pins 18, 25, and 45 to engine block ground. Resistance should be greater than 100k Ohms. If engine harness requires replacement, notify SRA. Measure resistance from actuator harness connector pins 19 and 29 to engine block ground. Resistance should be greater than 100k Ohms. If engine harness requires replacement, notify SRA.
ACTUATOR HARNESS: PINS 19 AND 29 TO ENGINE BLOCK GROUND >100K OHMS

b.

SENSOR HARNESS: PINS 18,25,45 TO ENGINE BLOCK GROUND >100K OHMS

USE TEST LEAD KIT P/N 3822758

T0126JCH

Figure 3. Oil Pressure/Temperature Sensor Voltage Test. 7. Place ignition switch in OFF position. Disconnect sensor harness and actuator harness from engine ECU. Disconnect oil pressure/temperature sensor and coolant level sensor jumpers. a. Measure resistance from sensor harness connector pin 18 to all other pins in connector. Resistance should be more than 100k Ohms. If engine harness requires replacement, notify SRA. Measure resistance from sensor harness connector pin 25 to all other pins in connector. Resistance should be more than 100k Ohms. If engine harness requires replacement, notify SRA. Measure resistance from sensor harness connector pin 45 to all other pins in connector. Resistance should be more than 100k Ohms. If engine harness requires replacement, notify SRA. Measure resistance from actuator harness connector pin 19 to all other pins in connector. Resistance should be more than 100k Ohms. If engine harness requires replacement, notify SRA. Measure resistance from actuator harness connector pin 29 to all other pins in connector. Resistance should be more than 100k Ohms.

b.

c.

d.

e.

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0017

ENGINE ELECTRONIC CONTROL UNIT (ECU) (794) TROUBLESHOOTING - Continued CORRECTIVE ACTION - Continued If engine harness requires replacement, notify SRA.
SENSOR HARNESS: PINS 18,25,45 TO ALL OTHER PINS >100K OHMS ACTUATOR HARNESS: PINS 19 AND 29 TO ALL OTHER PINS >100K OHMS

USE TEST LEAD KIT P/N 3822758

T0127JCH

Figure 4. Oil Pressure/Temperature Sensor Voltage Test. SYMPTOM ERROR CODE 1227 MALFUNCTION Sensor Voltage Supply Failure. CORRECTIVE ACTION 1. Place ignition switch in OFF position and disconnect sensor harness connector from engine ECU. a. Inspect engine harness and sensor connector for dirty, corroded, bent, broken, pushed back, and extended pins. Clean and repair connector(s) as required (Volume 2, WP 0267). Check engine harness and engine ECU connector for dirt or moisture in or on connector and for missing or damaged connector seals. Remove dirt and moisture from connector. Replace missing or damaged connector seals (Volume 2, WP 0267).

b.

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0017

ENGINE ELECTRONIC CONTROL UNIT (ECU) (794) TROUBLESHOOTING - Continued CORRECTIVE ACTION - Continued 2. Disconnect sensor harness and actuator harness from engine ECU. Place ignition switch to ON position. a. Measure supply voltage out of engine ECU sensor port at pins 18, 25, and 45 to ground. Voltage should be 4.75 to 5.25V. If voltage is not as specified, replace engine ECU (WP 0099).
4.75-5.25V SENSOR PORT 4.75-5.25V

ACTUATOR PORT

USE TEST LEAD KIT P/N 3822917

T0128JCH

Figure 5. Sensor Voltage Supply Test. b. Measure supply voltage out of engine ECU actuator port at pins 19 and 29 to ground. Voltage should be 4.75 to 5.25V. If voltage is not as specified, replace engine ECU (WP 0099).

3.

Place ignition switch in OFF position and disconnect sensor harness from engine ECU. a. Measure resistance from sensor harness connector pin 18 to all sensor harness connector pins. Resistance should be greater than 100k Ohms. If engine harness requires replacement, notify SRA. Measure resistance from sensor harness connector pin 25 to all sensor harness connector pins. Resistance should be greater than 100k Ohms. If engine harness requires replacement, notify SRA. Measure resistance from sensor harness connector pin 45 to all sensor harness connector pins. Resistance should be greater than 100k Ohms. If engine harness requires replacement, notify SRA.

b.

c.

0017-6

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TM 10-3930-675-23-1

0017

ENGINE ELECTRONIC CONTROL UNIT (ECU) (794) TROUBLESHOOTING - Continued CORRECTIVE ACTION - Continued
USE TEST LEAD KIT P/N 3822758 >100K OHMS

T0129JCH

Figure 6. Sensor Voltage Supply Test. 4. Place ignition switch in OFF position and disconnect sensor harness and OEM harness connector from engine ECU. a. Measure resistance from sensor harness connector pin 18 to pin 7 of OEM harness connector. Resistance should be greater than 100k Ohms. If engine harness requires replacement, notify SRA. Measure resistance from sensor harness connector pin 25 to pin 7 of OEM harness connector. Resistance should be greater than 100k Ohms. If engine harness requires replacement, notify SRA. Measure resistance from sensor harness connector pin 45 to pin 7 of OEM harness connector. Resistance should be greater than 100k Ohms. If engine harness requires replacement, notify SRA.

b.

c.

USE TEST LEAD KIT P/N 3822758

SENSOR HARNESS

>100K OHMS

OEM HARNESS

T0130JCH

Figure 7. Sensor Voltage Supply Test.

0017-7

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0017

ENGINE ELECTRONIC CONTROL UNIT (ECU) (794) TROUBLESHOOTING - Continued CORRECTIVE ACTION - Continued 5. If resistance was not as specified in Step 4, turn ignition switch to OFF position and disconnect 31-pin OEM harness connector (round) and OEM harness from engine ECU. Measure resistance from 31- pin OEM harness connector pin 7 to OEM harness connector pin 7. Resistance should be greater than 100k Ohms. If engine harness requires replacement, notify SRA.
>100K OHMS

OEM HARNESS

31-PIN OEM HARNESS

T0131JCH

Figure 8. Sensor Voltage Supply Test. 6. Place ignition switch in OFF position and disconnect actuator harness connector from engine ECU. a. Inspect engine ECU and actuator harness connector for dirty, corroded, bent, broken, pushed back, and extended pins. Clean and repair connector(s) as required (Volume 2, WP 0267). Check engine ECU and actuator harness connector for dirt or moisture in or on connector and for missing or damaged connector seals. Remove dirt and moisture from connector. Replace missing or damaged connector seals (Volume 2, WP 0267).

b.

7.

Place ignition switch in OFF position and disconnect sensor harness from engine ECU. a. Measure resistance from actuator harness pin 19 to all other pins in actuator harness. Resistance should be greater than 100k Ohms. If engine harness requires replacement, notify SRA.

0017-8

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0017

ENGINE ELECTRONIC CONTROL UNIT (ECU) (794) TROUBLESHOOTING - Continued CORRECTIVE ACTION - Continued

USE TEST LEAD KIT P/N 3822758

>100K OHMS

T0132JCH

Figure 9. Sensor Voltage Supply Test. b. Measure resistance from actuator harness pin 29 to all other pins in actuator harness. Resistance should be greater than 100k Ohms. If engine harness requires replacement, notify SRA.

8.

Place ignition switch in OFF position and disconnect actuator harness and OEM harness from engine ECU. a. Measure resistance from actuator harness connector pin 19 to OEM harness connector pin 7. Resistance should be greater than 100k Ohms. If engine harness requires replacement, notify SRA. Measure resistance from actuator harness connector pin 29 to OEM harness connector pin 7. Resistance should be greater than 100k Ohms. If engine harness requires replacement, notify SRA.

b.

USE TEST LEAD KIT P/N 3822758 >100K OHMS

T0133JCH

Figure 10. Sensor Voltage Supply Test.

0017-9

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0017

ENGINE ELECTRONIC CONTROL UNIT (ECU) (794) TROUBLESHOOTING - Continued CORRECTIVE ACTION - Continued 9. Turn ignition key to OFF position and disconnect 31-pin OEM (round) harness connector and OEM harness from engine ECU. Measure resistance from 31- pin OEM harness connector pin 7 to OEM harness connector pin 14. Resistance should be greater than 100k Ohms. If engine harness requires replacement, notify SRA.

>100K OHMS

OEM HARNESS

31-PIN OEM HARNESS

USE TEST LEAD KIT P/N 3822758

T0134JCH

Figure 11. Sensor Voltage Supply Test. SYMPTOM

ERROR CODE 1287 MALFUNCTION Sensor Voltage Supply Failure. CORRECTIVE ACTION Perform Troubleshooting Procedures for ERROR CODES: 1131, 1132, 1551, 1431, 1432, and 1443. Notify SRA.

0017-10

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0017

ENGINE ELECTRONIC CONTROL UNIT (ECU) (794) TROUBLESHOOTING - Continued

SYMPTOM ERROR CODE 1352 MALFUNCTION Sensor Voltage Supply Failure. CORRECTIVE ACTION 1. 2. Disconnect sensor harness from intake manifold pressure sensor and place ignition switch in ON position. Measure voltage from intake manifold pressure connector pin A to pin B. Voltage should be less than 4.5V. If voltage is not specified, replace intake manifold pressure sensor (WP 0118).

<4.5V

USE TEST LEAD KIT P/N 3822758

T0135JCH

Figure 12. Sensor Voltage Supply Test. 3. 4. Disconnect sensor harness from ambient air pressure sensor and place ignition switch in ON position. Measure voltage from ambient air pressure connector pin A to pin B. Voltage should be less than 4.5V. If voltage is not as specified, replace ambient air pressure sensor (WP 0118). Place ignition switch in OFF position and disconnect sensor harness from engine ECU. a. Inspect engine ECU and sensor harness connector for dirty, corroded, bent, broken, pushed back, and extended pins. Clean and repair connector(s) as required (Volume 2, WP 0267). Check engine ECU and sensor harness connector for dirt or moisture in or on connector and for missing or damaged connector seals. Remove dirt and moisture from connector. Replace missing or damaged connector seals (Volume 2, WP 0267).

5.

b.

0017-11

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0017

ENGINE ELECTRONIC CONTROL UNIT (ECU) (794) TROUBLESHOOTING - Continued CORRECTIVE ACTION - Continued 6. 7. Disconnect sensor harness from engine ECU and place ignition switch in ON position. Measure voltage from engine ECU connector pins 17 and 37 to ground. Voltage should be 4.75 to 5.25V. If